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I860 1914 

DENVER, COLORADO. 

U.S.A. 
































































































































































Established 1860 


Catalogue No. 12-F 


Some Details as to Smelting 
Practice and Equipments 


The Metallurgical Principles which Underlie, 
and the Apparatus which Accomplishes the Recovery of 
Lead, Copper, Gold and Silver from their 
Ores by Fire Methods 


Copyright 1914 by Colorado Iron Works Co. 


Colorado Iron Works Co. 

Denver, Colorado, U. S. A. 



Private Exchange Telephone Main 3380 

Cable Address: “Nesmith, Denver.” Codes: Lieber’s, Bedford McNeill’s, 
Moreing & Neal’s, A. B. C. (fiftl\ edition). Western Union, Directory 





i! I0|<! 

©ci.A371 775 


IT 


PLANT OF COLORADO IRON WORKS COMPANY, DENVER, COLORADO. 








ANNOUNCEMENT. 


We issue separate catalogues of the iiiaeliiiierv and a])])aratu3 
which we luauufacture for use in the treatment of ores bv amalga¬ 
mation, concentration, cvanidation and smelting. This one is de¬ 
voted to smelting, and is designed to illustrate and descril)e a suffi¬ 
ciently wide variety of our productions to acquaint onr friends and 
the public with the nature of our line, and to be usefnl in the dis¬ 
cussion of matters between them and ourselves. 

It has become a settled practice with us to preface each of our 
catalogues with a description of the ]^rocess to which it is devoted, 
and these, though necessarily l)rief, are accurate so far as they go and 
they are thought to go far enough for the purpose. Those expecting to 
embark in smelting will, if they be without previous experience, 
find in the article in tliis catalogue just what they need to inform 
them of the fnndamentals necessary to an understanding of the sub- 

o 

ject, and if disposed to go exhaustively into the details of it, they 
will have lost nothing by the preparation they here receive for the 
standard textbooks. 

It is always difficult in tlie ])reparation of onr catalogues to 
place a limit on their size and at the same time show the more im- 
])ortant portion of our line. From the present edition of our smelter 
catalogue much is omitted which might be presented, dne to its being 
crowded out by new, and what has been regarded more important 
matter. The failure to find anything in the smelting line which is 
sought among its pages should therefore not he taken as an indica¬ 
tion that we are not prepared to supply it. 

We design and equip plants for the reduction of ores by all mod¬ 
ern processes and in addition we will engage to erect them complete, 
demonstrating their efficiency in practical operation. 

We endeavor to have our illustrations correctly represent the 
various machinery, hnt in the advance which is continually being 
made in efforts to improve it, changes in detail are made from time 
to time. As these are in the interest of the purchaser, we feel that 
an apology on this acconnt is perhaps superflnons. 

Onr aim has always been the production of a high-grade line of 
machinery, the prices l)eing made as low as consistent with high 
quality. In no case do we attempt to build a machine to come within 
a certain price and place it in the field of competition with others 
having low first cost as their chief merit. It is this policy, consis¬ 
tently maintained for fifty years, that has established onr enviable 
reputation. 

COLORADO IROX WORKS CO]\rPAXY. 



4 


OUK FACILITIES^ TFILMS, ETC. 


COLORADO 

IRON WORKS CO 


REPAIR WORK. 

We desire to call particular attention to the promptness with 
which repairs and renewals can be made at oiir works. Our foundry 
and machine shops are ample and no delays need he anticipated. 

Our advantag’es are a])])arcnt to our smelting’ friends in the 
Kocky Mountains, as from three to fourteen days are sayed in procur- 
ing sup})lies from Denyer direct. We haye telephone connection with 
nearly all mining camps in Colorado and adjoining States, and pref¬ 
erence is always giyen renewal orders, as we fully realize the im¬ 
portance of kee])ing a plant running. 

In ordering repairs be yery specific and giye numbers where 
possible. Make measurements carefully, and wdien possible giye a 
rough sketch, no matter how crude. Where practicable refer to cata¬ 
logue number for details, etc. ' 

TERMS. 

Our terms to remilar customers with established credit are 
monthly settlements. On new business, for equipment only, one- 
third to one-half cash with order, balance when ready for shipment. 
On new business, for equipment and erection, one-third to one-half 
cash with order with special arrangements as to payment of the bal¬ 
ance. On special Avork done to order, cash in adyance or part cash 
in adyance and an ample guarantee to secure payment of the balance. 

Remittances should he in Denyer or I4eAy York funds or their 
equiyalent. We pay no exchange. 

SHIPPING DIRECTIONS. 

Shipping directions should he explicit and state Ayhether by 
freight or express. If not otherwise instructed, all material Avill be 
shipped by freight, except light packages, Avhich Ayill he forwarded 
by express. 

Our responsibility ceases Ayith deliyery to the carrier in good 
order. In the eyent of loss or damage in transit, the agent of the 
carrier should be immediately notified. We Ayill render all assistance 
possible in adjusting the claims of our customers for losses, damage 
and excess charges. 




COLORADO 

IRON WORKS CO 


THE SMELTING I’ROCESS. 


5 


PREFACE. 

On the following pages we present short descriptions of lead 
and copper smelting, in Avliich Ave aim to furnish sufficient informa¬ 
tion to those Avithont preAdons knoAAdedge of the process, to enable 
them to nnderstand the nnderljing principles, and to render a dis¬ 
cussion of smelting intelligible to them. A further purpose is to 
dispel the far too preA^alent belief that smelting is an intricate process 
and not generally aA^ailable by reason of extreme complication. Tbe 
rcA^erse is actnallA^ the case. In former A^ears an air of inystei’A' AA^as 
nndonbtedly cast about the subject, the effect ol Avhich still persists 
to a certain extent, but as a matter of fact it is no more difficult of 
application than many AA^et extraction methods and offers the adA^an- 
tage that results can be foretold from analyses of the ores AAoth an 
exactness not approached by tests of any Avet methods. The product 
of smelting is nearer the finished product than is the product of 
many other processes, the cost of plant no greater, and smelting in 
many cases is the most economical. The use of the smelting process 
has to some extent been restricted to ores AAdiich could not be treated 
by any other process. This is a graA^e mistake, as the smelting 
process should AAoth rare exceiitions be used AAdiereA^er it Avill apply. 

To accomplish onr purpose A\dthin the space here aA^ailable, Ave 
haA^e been obliged to confine onrseh^es to fundamentals and to omit 
much AAdiich although interesting is not essential to a general under¬ 
standing of the subject. Those experienced in smelting operations, 
therefore, need not expect to find anything ucav, and others, if they 
desire to pursue the subject further, may do so in the A^arious AA-orks 
deA^oted to it. In the chapters on ^‘Ilot Blast’’ and on “Vaporization 
of Jacket Water’’, hoAA^eA’er, AA^e jiresent the adA^antages of tAA^o systems 
to AAdiich AA^e liaA^e s^iA^en much study, and tbe adA^antages of AAdiich 
AAT feel are not appreciated as they should be, mainly because they 
haA^e not as a rule been properly presented. The reading of these 
chapters by experienced smelter operators is, therefore, especially 
solicited. 

In the introductory chapter AA^e haA^e endeaA^ored to accomplish 
our purpose AAuthout assuming a knoAAdedge of chemistry on the part 
of the reader,‘and AAdiile this precludes the use of formulae in ex¬ 
plaining the reactions AAdiich take place, they are not here so necessary 
as in the treatment of the subject in a more exhaustiA’^e manner. 


0 


THE s:\rEi/riNCr teocess. 


COLORADO 

IRON WORKS CO 


The Smelting Process. 

Smelting in the broadest sense was practised in pre-historic 
times, bnt as this article is not intended to be a history of the pro¬ 
cess, bnt an elementary description of existing practice, we will pro¬ 
ceed to a consideration of the reactions which take place in copper 
and in lead smelting with special attention to the blast furnace, owing 
to its more general application and wider use. 

Blast furnace smelting of copper and lead ores has been brought 
to its highest state of development in America, and the method as 
now practised may be said to have come into use by successive im¬ 
provements instituted within the past thirty years. 

What contributed more than anything else to place smelting 
on its present firm foundation was the application of chemical con¬ 
trol to the operations in place of the hap-hazard methods of earlier 
years. The chemical reactions taking place in smelting and the 
factors influencing economical w’ork are now well understood, wdth 
the result that the availability of the process for a given ore can 
be predicted with certainty and the operation of smelting so con¬ 
ducted that the most economical Avork can be carried on. 

To those Avithout knoAvledge of the principles underlying the 
smelting process, the saving of the gold and silver of an ore is the 
feature of greatest interest. The applicability of the process de¬ 
pends, hoAvever, not on the metals, but on the gangue, and Ave Avill 
proceed to a short description of Avhat takes place in the blast fur¬ 
nace, Avith a vieAV to making this matter clear. 

Slag Formation. 

The elements entering into the composition of ores are either 
acid-forming or base-forming elements, and slags are compounds of 
acids and bases formed under the conditions prevailing in the fur¬ 
nace Avhen proper relative quantities of acids and bases are present. 
The most common substance of a composition analogous to slag is 
glass. Ordinary AvindoAv glass, for example, is formed by the fusion 
in pots of a mixture of quartz sand, soda and lime. The transparency 
and colorlessness of glass is secured mainly by the choice of the 
ingredients and their purity, and as these qualities Imxe no im¬ 
portance in slags, the latter are black, or nearly so, from the oxides 
of the lieaAw metals Avhich form a part of them. The luster of slags 


COLORADO 

IRON WORKS CO 


SLAG FOiniATION. 


7 


varies from glassy to stony on fracture wlien cold, the appearance 
when hot also varies considerably and these physical signs mean 
mnch to experienced blast furnace men, hnt a discussion of them 
wonhl he ont of place here. 

Ihe one great acid constituent of slags is silica and the prin¬ 
cipal l)asic constitnents are iron oxide and lime, with minor amonnts 
of other bases, among which the principal are magnesinm and man¬ 
ganese. Xone of the ordinary ore constitnents bv itself is fnsible at 
smelting temperature, but the slags formed l)y their coml)ination 
with each other are fnsible and it is owing to this circnmstance 
that the smelting process is practicalde. If, therefore, a proper 
mixture of silica, iron oxide and lime is placed in a blast furnace, 
together with fuel for the prodnction of the necessary heat and air 
for the combustion of the fuel is applied in the form of blast, the 
iron oxide and lime will combine with the silica, forming an iron 
and lime silicate which will melt and flow away from the remaining 
solid portion of the charge, leaving fresh portions to come in con¬ 
tact with each other and combine, and the process will be continnons 
if the charge and fuel are replenished and the molten slag with¬ 
drawn. This is the reaction which makes smelting possible, and 
while it is actually somewhat more complicated than as just de¬ 
scribed and is accompanied by other reactions of which snl)seqnent 
mention will he made, it is the fnndamental conception, Avhich kept 
in mind, Avill make smelting processes easily understood. 

If there w^ere no other purpose than mere melting, the quantity 
of fuel nsed wonld be the amount required for the prodnction of the 
necessary heat, and the amount of air supplied by the blast wonld 
be that snthcient for the comhnstion of the fuel. The air wonld be 
supplied at such a rate as wonhl cause the combustion to take place 
with the necessary violence to maintain the required temperature. 
How the quantities of fuel and blast are inflnenced by the results 
desired to be obtained Avill ai)pear as we proceed. 

Fortnnately for the practical nsefulness of the smelting pro¬ 
cess, there is considerable latitude in the proportions in Avhich silica 
will combine with bases to form slags, and in practice such a slag is 
therefore made as Avill produce the l)est net result in view of all the 
conditions. Distinct conceptions mnst be retained of two character¬ 
istics of every slag and these are the formation temperatnre and 
the melting tem])eratnre. Silica and iron oxide not only Avill not 


8 


COLOfl^DO 

IKON WORKS CO 


COPPEK MATTE SMEETINfE 

combine at ordinary temperatures, but on raising the temperature 
they will not combine until a certain point is reached. This point 
is the formation temperature of the slag and consequently the smelt¬ 
ing operation can not proceed unless the temperature within the fur¬ 
nace is sufficiently high to cause the formation of the slag due to 
the ore mixture. 

To he considered apart from the formation temperature of a 
slag is its melting point. This is the teni})erature at which a slag 
melts and the temperature wdthin tlie furnace must he sufficiently 
high to keep the slag in a fluid condition so that it will flow from 
the tap hole. Although the formation temperature and melting 
temperature are relatively close together they are not the same and 
two different conditions arise on this account. Where ^e forma¬ 
tion temperature of the slag is above its melting ])oint we have a 
condition in which it can he readily tapped from the furnace, hut 
where the melting point is higher tlian the formation temperature, 
slag will form and remain in a viscous state and will not flow with¬ 
out the application of more heat. In the one case we have a safe 
slag and in the other a slag with wdiich there is constant danger of 
freezing up the furnace. To he adapted to smelting, an ore must 
consequently^ contain silica, iron and lime in such proportions as 
will make a suitable slag, or if deficient in any of them, other ores 
or fluxes must he added. Detrimental compounds, as of zinc and 
aluminum are sometimes present, and if in large quantity they will 
cause trouble. For this reason it is necessary that their amount he 
determined, if present, and that they he considered in deciding the 
feasibility of smelting. 

Copper IMatte Smelting. 

Assuming in addition to a properly proportioned mixture of 
silica, iron oxide and lime, a certain amount of a copper sulphide min¬ 
eral, chalcopyrite, the slag will form as already described and, 
neglecting for the moment any action of the blast and fuel other 
than the production of heat, the chalcopyrite Avill melt and trickle 
doAvn through the charge to the hearth of the furnace. On the 
hearth of the funiace the melted chalcopyrite, now a co]iper-iron 
matte, Avill sink into- the molten slag by reason of its greater spe¬ 
cific gravity and collect in a separate layer, much as oil and water 
separate Avhen mixed and then allowed to stand. With tap holes at 
two levels, the matte can he drawn from one and the slag from the 



COLORADO 

IRON WORKS CO 


9 


C()I‘1»EK :\rATTE S:S[ELTING. 

Other, hut it is customary to let both slag and matte How together into 
an outside settler or forehearth where they can se})arate undisturhed 
l)y such unfavorahle conditions as exist within the furnace. 

Co})})er matte is a mixture of co])|)er sul])hide and iron sul¬ 
phide in variable proportions, together with an admixture of im¬ 
purities among which are the gold and silver of the ore. It has a 
\ ery strong affinity for the precious metals and will collect practically 
all of the gold and 95 per cent, or more of the silver, and it is, there¬ 
fore, only necessary to consider the slag and the matte. 


FIG. 1. INTERIOR OF A EARGE COPPER SMELTER IN ARIZONA. 

In tlie simple illustration of matte formation just given, it 
was assumed that the iron and copper sulphides Avould melt down 
without change. This is not true nor is it desirable that they should 
do so. Both iron and co])})er have a strong affinity for sulphur, but a 
stronger affinity for oxygen, and at the temperature prevailing in 
the blast furnace both iron and copper sulphides are rapidly converted 
into oxides through the burning of their contained sulphur in the 
oxv£i*en of the air blast. In addition to the combustion of sulphur a 
part of the sul])hur of the iron sul]ffiide is so loosely hound to the 












10 


COLORADO 

IRON WORKS CO 


COPPER ]MATTE S:\IELTING. 

metal that it is driven off by the mere heating to which the ore is 
subjected in the upper zones of the fnrnacej about one-half of the 
snlphnr of pyrite being thns eliminated. Copper has a greater 
affinity for snlphnr than iron and in consequence of this the copper 
will remain in combination with part of the snlphnr which has not 
been burned off' and iron will continue in coml)ination with such 
remaining portion of the snlphnr as is not required to satisfy the 
affinity of the copper. Thns, the net result is that snlphnr is lost 
by the iron sulphide and the matte resulting from the smelting is 
increased in its percentage of copper. The gold and silver col¬ 
lected from the ore by the molten sulphides remain with the copper 
thronghont, and the concentration of the copper in the matte by 
the burning off of snlphnr is accompanied by a corresponding con¬ 
centration of the gold and silver. 

The oxygen which enters the furnace in the blast ])artly goes 
to burn the fuel. The iron sulphide is partially burned off by re¬ 
maining oxygen, the snlphnr forming snlphnr dioxide gas which 
passes off by the stack and the iron also combining with oxygen to 
form iron oxide in Avhich condition it enters the slag. The degree 
of concentration which can thns be bronaht about bv the biirnins: 
of sulphur and iron is limited by the time during which the molten 
sulphide is exposed to the action of the oxygen, and this is short, 
being the time required in trickling down from the point where 
melted to the hearth of the furnace; as when it reaches the hearth 
it sinks below the slag which protects it from the action of the blast. 

The atmosphere within the copper matting furnace is therefore 
an oxidizing one, that is, an excess of air is blown into the furnace 
over what is necessary for burning the fuel, this excess being largely 
consumed in the oxidation of snlphnr and iron. A\Tiere the per¬ 
centage of snlphnr in the charge is high, a great volume of blast is 
supplied in order to oxidize as much of it as possible and thereby 
produce a high grade matte. In copper matte smelting the quan¬ 
tity of carbonaceous fuel used is also interwoven with the amount 
of sulphur in the charge; the greater the amount of sul]ffiur the less 
fuel is required. This is due to the fact that in the oxidation of sul¬ 
phur and iron large quantities of heat are developed, indeed, fur¬ 
naces running on practically pure pyrite with only enough silica to 
flux the iron oxidized have been kept in operation for several davs 
without any carbonaceous fuel wliatever. This is running too close 


COLORADO 

IRON WORKS CO 


11 


COPPER ]\rATTE SMELTING. 

to the danger line^ however, and it is ciistoinary to charge a very 
small amount of coke, although less than one per cent, suffices to 
keep the furnaces in satisfactory running order at a plant where 
the conditions are favorable. This is what is known as pyritic 
smelting. 

The effect of the sulphur in the ore will now be understood 
in a general way. That which is not burned off' clings to the copper 
and iron, more tenaciously to the copper than to the iron, so that 
the only iron in the matte is the amount necessary to satisfy the 
affinity of that part of the sulphur which is not required by the 
copper. One pound of sul})hur combines with four pounds of cop¬ 
per, forming live pounds of copper sulphide, and one pound of sul¬ 
phur combines with one and three-quarters pounds of iron, forming 
two and three-quarters pounds of iron sulphide. In a matte calcu¬ 
lation, therefore, the amount of sulphur eliminated is deducted from 
the total sulphur in the ore, one pound of this remaining sidphur is 
set apart for every four pounds of co]>per and one and three-quarters 
pounds of iron for each pound of sulphur not combined with the 
copper. The grade of the matte, that is the ratio of concentration, 
depends on the amount of sulphur eliminated and it is for this rea¬ 
son that as much sulphur as possible is oxidized if there is an ex¬ 
cessive amount in the ore charge. Sulphur is not always in excess, 
however, and in such cases what sulphur there is has to he con¬ 
served in order that a matte of too high grade be not made, as this 
would entail high losses of copper in the slag. The best grade of 
matte for treatment by converting is one containing about 45 per 
cent, copper and under ordinary conditions it is sought to jiroduce a 
matte of about that tenor. 

The above described process of slag and matte formation is all 
that it is really necessary to know in order to understand the gen- 
eral principles underlying copper matte smelting. Other elements 
than those mentioned are present in ores and some of them, if in 
large amount, call for special manipulation; hut these are matters 
within the sphere of a competent metallurgist and their considera¬ 
tion here Ayould lead us beyond the intended scope of this article. 

Cbpper matte smelting is also carried on in reyerberatory fur¬ 
naces. The principles underlying this operation are the same as 
in blast furnace smelting, hut the ore must be ffne and, as there is 
practically no elimination of sulphur in the reyerberatory, the 


12 


COLORADO 

IRON WORKS CO 


coppp:k matte S]melting. 

aiiiouiit of this element in the charge must he made just sufficient 
to produce the desired grad© of matte. Keverberatory smelting is 
usuallv restricted to concentrates which are too tine to charge into 
the blast furnace and, where both blast furnaces and reverberatories 
are in use at the same plant, the latter also receive the flue dust 
produced by the blast furnaces as Avell as other fines, thus leaving 
only coarse ores fo-r the blast furnaces, thereby increasing their 
capacity and smoothness of operation. 

The cost of smelting in reverberatories is generally consider¬ 
ably higher than in blast furnaces, due to the less efficient method 
of applying the heat, the necessity of preliminary roasting and 



FIG. 2. A SMALL COPPER SMELTING PLANT IN MEXICO. 


various other unfavorable features, such as increased labor and cost 
of maintenance. While this is true under ordinary conditions, it 
is but fair to state that where conducted on a very large scale with 
the generation of steam from the waste heat, such steam hein<^ cred- 
ited to the cost of smelting, the disadvantage of the reverberatorv 
from the standpoint of economy is a very slight one. Such results 
are obtained, however, in not more than five or six plants in America. 

In reverberatory furnaces, the fuel is either coal or crude oil, 
hut producer gas if sufficiently high in comhustihles, gives results 
as good as or better than coal, as with coal there is considerable un- 


COLORADO 

IRON WORKS CO 


COPPER MATTE SMELTING. 


13 


avoidable loss of heat in firing and reinovinc; clinkers from the <>:rate. 
It ninst not be understood from this that gas producers are with¬ 
out their drawbacks or are applicable in all cases. The fuel should 
be suitable for gas producer use. Wood has been nseil direct Avith 
some success, but is not to b© considered if coal or oil is available. 
Whatever the fuel, the temperature Avhich must be obtained is so 
high tha t a very strong draft and intense combustion must be con- 
tinnouslv maintained. The coal is burned in a fire-box at one end 
of the furnace and a very deep bed is carried on the grates, the 
fire-box is thus essentially a gas producer and additional air to 
complete the combustion is admitted at the bridge Avail. Neither 
coke nor charcoal is suitalde and the coal should be of the long 
flame, ^T’at” Auriety. 



FIG. 3. SLAG DISPOSAL AT A LARGE ARIZONA COPPER SMELTER. 

Crude petroleum and the cheap by-})rodncts of its distillation 
are used Avith Aury great success in reAurberatory smelting furnaces. 
With oil fuel there is no difhcnlty in maintaining the desired tem¬ 
perature and in getting the heat Avhere Avanted. The furnace is not 
exposed to the unaAuidable admission of cold air as is the case Avhen 
firing and cleaning grates in furnaces using solid fuel. 

Co])per matte is the shijAping product from smelters of moder¬ 
ate size as the concentration attained in the smelting reduces the 








('OPI’KK :\rATTE S:\rELTTNC;. 


COLORADO 

IRON WORKS CO 


U 


quaiitity of material to be handled to a ])oint where its further 
treatment on the ground would not he economical. Jt is only at large 
plants that the matte is converted to metallic copper and it is ordi¬ 
narily carried only to blister cop])er, the im})nre product formed by 
blowing air throngh the molten matte in converters. In remote 
localities Avhere freight rates are al)norniallv hi<>h it mav be advis- 

O c • 

able to add a converting plant operating on a scale which would 
not be economical were the ])lant more favorably situated, l)ut such 


conditions are rare. 

In converting, the sid})hur and iron are oxidized, the sulphur 
l)assing otf as sulphurous acid gas and the iron oxide combining 
with silica Avhich has to l)e su])plied. As the process has been con¬ 
ducted in the past the silica is in the form of very highly silicious 
ore, crushed and tamped into place as a refractory lining for the 
converter, and it is upon the lining that the iron oxide draAvs for 
its silica. For commercial reasons diw" silicious c'old and silver ores 
are used for this })urpose Avhercver obtainalde, as in the process the 
precious metals are recovered. 


At present, converting is ra])idly undergoing a transition from 
this 'bicid” process to Avhat is knoAvn as ^‘basic” converting. Here 
the converter lining is formed of a strongly basic refractory, usually 
magnesite brick, and the silica is charged in the form of coarse sili¬ 
cious ore. 


Where con Averting is ])ractised, the blister coi)per is cast into 
moulds and shipped to a refinery. The couA^erter slag may be added 
to the furnace charge for its high iron content if iron is short there, 
but the usual practice is to add it directly to the settler, as it is 
very fluid and any entrained cop])er readily settles out. 

The retining of blister copper in America is uniA^ersally by 
electrolysis and as the scale of operations is necessarily very large, 
about a dozen plants handle the entire ])lister copper output of the 
country. Electrolytic refining is conducted in vats, Avitli copper sul¬ 
phate as the electrolyte, the blister copper forms the anode, the pure 
copper deposits on the cathode, and the impurities, ueglecting small 
quantities of certain of them Avhich go into solution and gradually 
foul it, collect on the bottom of the vat as the ^kanode mud”. This 
anode mud contains the gold and silver. 


COLORADO 

IKON WORKS CO 


15 


BLACK COPPEK SMELTING. 


Black Coppeii Smelting. 


When tlie surface ores of copper, mainly oxides, carbonates and 
silicates are smelted, the product is impure metallic copper, known 
as “black co])])er.'’ The process is not ])ractised to a great extent 


owing to high slag losses. 


The operation here is a reducing one; that is, an excess of coke 
is used, the ores giving up their oxygen to the reducing atmosphere 
and the metal falling to the hearth in the same manner as the matte 


does in smelting ores liigh in snlphnr. On the hearth, the metallic 
copper is protected by a layer of slag, hut in trickling down throngh 
the charge from the point where it is melted it must pass through 
the tuyere zone, Avhere it is momentarily exposed to oxidation, and 
here some of the copper Avhich has been reduced in the upper zones 
of the furnace is reoxidized and enters the slag as a silicate. Thus, 
copper oxide enters the slag, not only by reason of incomplete re¬ 
duction in the upper zones of the furnace, but also by reason of 
reoxidation of reduced copper in the region of the tuyeres. In addi¬ 
tion to the copper lost in this Avay, some metallic copper in an ex¬ 
tremely tinely divided condition is retained in suspension by the 
slag and, taken together, these losses make a total Avhich is prohib- 
itiA^e in many cases. 

The smelting operation proceeds rapidly, the slag formation 
takes place in the same manner as in c(>p])er matting, except that 
the iron is already in an oxidized condition, and gold and sih^er, if 
present, remain Avith the copper. The metallic copper, being a good 
conductor of heat, chills easih^ and for this reason the furnace is 
built Avith a crucible designed to prevent excessive radiation, and 
the black copper is tapped directly from this crucible into moulds. 


Lead Saielting. 

Lead smelting differs from copper matting in that the product 
is metallic lead alloyed Avith other metals. In this respect it is 
analogous to black copper smelting. Smelting to metal necessitates 
the maintenance of a reducing atmos])here in the furnace, and sul¬ 
phur elimination is thus impossible. Lead sulphide, galena, is 
already in the form of sulphur combination highest in lead, and if 
smelted in an oxidizing atmosphere as in copper matting, the galena 
Avonld mostly melt dowm unchanged, as but little sulphur Avould be 
eliminated ])v the bessemerizing action to Avhich it Avoiild be sub- 
jected, and although a concentration Avould be effected, the product 


10 


COLOR ADO 

IRON WORKS CO 


l.EAl) S:MKT/nNG. 

would he an undesirable one. A result which woidd he fatal to such 
snieltin<)’ as a ])rotitahle enterprise would he caused hy the fact tliat 
such lead as Avas freed from sulphur would either he ATjlatilized and 
|)ass oft hy the stack, carrying’ ])recious metals with it, or enter the 
slag as lead silicate. 

Tluis we have as the first recpiisite, a reducing atmosphere Avithin 
the furnace, and as the second, a Ioav sul])hur content of the charge. 
The surface ores of lead are smelted raAv, as they are practically 
free from sul]diur, Imt as de])th is gained sulydiur appears and the 



FIG. 4. A UARGE CUSTOM LEAD SMELTER IN AVESTERN COLORADO. 


ores must he roasted preliminary to smelting. At custom plants 
galena ores are sometimes smelted raAv Avhen the silver content is 
high, to aA’oid A’olatilization losses in roasting, hut as the other ores 
in the charge must he more completely roasted to keep doAvn the 
percentage of sulphur in the or© mixture, this is not strictly an 
exception to the above rule. 

The roasting of lead ores is an expensiA’e operation, the cost 
increasing greatly as the last remaining sulphur is sought to be 
eliminated. IIoAvever, if some cop])er is present in the charge it 













COLOR ADO 

IRON WORKS CO 


I.EAD SMELTING. 


17 


permits higher sulphur to be carried than would otherwise he pos¬ 
sible, thus reducing the expense of roasting. For this reason all lead 
smelters now endeavor to carry a small percentage of copper in the 
charge, and in addition to base bullion, a certain amount of matte 
is produced. J his matte is composed of the sulphides of copper, 
lead and iron, and besides taking care of a moderate amount of 
sulphur, it assists in reducing slag losses. 

1 he matte is crushed and roasted, almost universally in hand 
rabbled reverberatory furnaces, and wlien sutHcient has accumulated 



FIG. 5. A LARGE LEAD SMELTING PLANT IN MISSOURI. 


it is concentrated to a shipping product. Sometimes a small copper¬ 
matting furnace is used for this special ])urpose, but usually, in 
plants operating a number of furnaces, one of the lead stacks, the 
one wdiich is in the poorest condition, is put on a matte charge to 
work up this product. 

The lead smelter has not so wide a latitude in the character 
of the slags he can run as the copper matte smelter has. Tie must 
adhere rather closely to certain type slags wdiich experience has 
shown to he suitable in order to keep the slag losses low. In blast 


















18 


COLORADO 

IKON WORKS CO 


LEAD SMELTING. 


furnace smelting to lead base bullion, when smelting for gold and 
silver, which is the class of lead smelting most generally })ractised 
in America, the slags contain from 0.75 per cent, to 1.50 per cent, 
lead. The silver in the slag will run below one ounce per ton, hut will 
exceed this if the bullion values are very high, say over 300 ounces 


per ton. Lead slags can he made much cleaner than this hut the 
present tendency is to rapid driving, the additional tonnage put 
through more than compensating for the additional losses. Gold 
is all recovered in the bullion, and custom smelters, as a rule, actually 



FIG. 6. A LARGE CUSTOM LEAD SMELTER IN EASTERN COLORADO. 

show a plus gold recovery, hut this is due to traces and small amounts 
in various ores, which are not paid for. 

Zinc is ohjectionahle in lead smelting from its causing loss of 
silver hj^ volatilization Avith it, hut only part of the zinc is volatilized 
and if in considerable quantity it greatly disturbs the operation of 
the furnace by the formaton of accretions and by reducing the fluid¬ 
ity of the slag. Especially will zinc cause trouble with the slag if 
alumina is at the same time present. Either zinc or alumina is 
sufficiently ohjectionahle when alone, l)ut when both are in the charge 
the difficulties are greatlv increased. 

o «/ 




COLORADO 

IRON WORKS CO 


I.EAD SMELTING. 


10 


Arsenic, Mliicli is mostly oxidized in the copper matting fur¬ 
nace, is not eliminated in the reducing atmosphere of the lead fur¬ 
nace*, and if in considerable amount, will form speiss, which has a 
strong athnity for the precious metals and is a by-product difficult of 
treatment. 

Lead furnaces are always built with a crucible in which a large 

hodv of molten lead is continually carried. The crucible is con- 

» ♦ 

nected with a lead Avell exterior to the* jackets by a channel, and it 
is from this lead well that tlie bullion is dip]ied, or alloAved to floAv 
in the case of lare-e furnaces carryin«‘ considerable lead in the charge. 
l"pon the lead is the matte and n])on this the slag. Speiss, if made. 



FIG. 7. SLAG DISPOSAL AT A LARGE COLORADO LEAD SMELTER. 

forms a layer between the matte and the lead. The slag and matte, 
and speiss, if any, are all tapped from the furnace together, and 
separated in a forehearth. 

Coke is the fuel of tlie lead blast furnace. Charcoal, if of the 
liest, Avill ansAver AAdiere coke can not be had, but is ordinarily not 
to be considered as a substitute for it. In yery many cases cliar- 
coal has been used to replace about half of the coke AAuthout detri¬ 
ment and this may be of great adyantage in some circumstances. 

In Europe, lead concentrates are smelted to some extent in 
reyerberatory furnaces. The conditions necessary to the success of 
this are a charge yery high in lead, TO per cent, being common, not 
oyer T per cent, or 5 per cent, silica, and other impurities must 
be present onh" in yery small quantities. In addition to the character 





20 


SAMPLING. 


COLORADO 

IRON WORKS CO 


of the charge, a great deal of fuel is required, the capacity is very 
low, and skilled labor is required. 

Where galena ores are so low iu silver that desilverizing the 
product obtained from smelting them would be unprofitable, the 
galena, in the form of concentrates, may be first treated in Scotch 
hearths, whereby about half of the lead is directly recovered, the 
balance being partly volatilized and partly retained in a roasted and 
sintered product, the gray slag. The gra}-' slag is smelted in the blast 
furnace, for which it forms an ideal charge and the fume from the 
hearths is recovered in a bag house. The method is cheap and 
efficient when smelting for lead where the cost of labor is low, as 
preliminary roasting is dispensed with; but its use is precluded on 
galena containing silver owing to volatilization losses. 

Except in large plants, the base bullion is ship]ied to a refinery 
where it is desilverized, almost universally by the Parkes process. 
This consists in adding zinc to tlie molten lead, mixing thoroughly, 
and then cooling. Before the lead solidifies, the zinc separates as a 
crust on the top of it and this zinc crust contains most of the pre¬ 
cious metals. The operation is repeated, each zincing reducing the 
precious metal remaining in the lead, until a point is reached where 
the values recoverable no longer warrant their separation. 

Cupellation offers advantages as a further local treatment for 
base bullion under certain circumstances. Conditions where it is 
applicable at a small or moderate size plant are insufficient lead 
for the blast furnace charge or very high cost of shipment on base 
bullion, especially if in a locality where lead is of little value. The 
products of the cupellation are then litharge, which is returned to 
the blast furnace to furnish a collector for precious metals, and a 
shipping product of dore bullion, which is silver bullion containing 
gold. 

Sa:mpltng. 

ATitomatic sampling has been developed in America to such 
perfection that the reliability of the work of a properlv designed 
and equipped sampling plant is unquestioned. The underlying prin¬ 
ciples of sam]ding liave received close study by American metallur¬ 
gists with the result that the necessary conditions for accurate and 
concordant work liave become well known. 

The important features of accurate sampling are to remove a 
relatively large portion at each division and to recrush after each 


COLORADO 

JRON WORKS CO 


SAMPLING. 


21 


cut, so that the size of the lumps of ore bear a proper relation to the 
size of the lot being- sampled. To be reliable, an automatic sam])- 
ling machine must remove a part of the whole stream coming to it by 
cutting' it intermittently. Sam]ders which divide the stream are 
absolutely unreliable, as it has been found impossible to prevent 
concentration of values in a part of the ore stream. 

Sampling plants vary in the arrangement of the equipment, and 
their completeness depends upon the class of ores handled; but 
they should in all cases conform to the principles given above. Thus 
a custom smelter should have and is expected to have a plant capalde 
of very exact work, but a smelter handling ores from its own mines 
needs only such sampling equipment as necessary to furnish relial)le 
data for computing the furnace charges and providing a satisfactory 
check on operations. 

Coming to a custom plant are often dry silicious ores which 
are frequently spotty and difficult to sample. Accuracy here is nec¬ 
essary to arrive at a just settlement with the shipper. For making 
up furnace charges the important constituents are all present in 
relatively large quantities and there is not the same liability to error 
as in sampling gold ores where the amount of gold to l)e deter¬ 
mined may be only an ounce or two in a ton. It is not intended 
to belittle the importance of accurate sampling at a private plant, 
as it is necessary if a close check is to be kept on operations. The 
point desired to be brought out, however, is that at a plant erected 
by a mining conqiany to smelt its own ores, an elaborate sampler 
is not essential to the operation of the smelter, l)ut only as a check 
on the work, and that a sampling plant can, therefore, be added at 
anv time. The assavs of the furnace products will show the sav- 
ing and the loss, and this will suffice during the early stages of 
operation where it is desired to defer the expenditure of the money 
required for a sampler. 

The illustration herewith shows the side elevation of an auto¬ 
matic sampling works for crushing and sampling gold ores in connec¬ 
tion with a custom smelter. The ore is taken from the cars and 
shoveled into the crusher, after passing which it is elevated to the 
first automatic sampling machine which removes one-fifth of the 
Inilk as a sample, the rejected ore l)eing elevated to a swivel spout 
which discharp’es it into anv one of the bins on the second floor, 
where it can be held, if necessary, pending settlement; after which 


^•2 


COLORADO 

IRON WORKS CO 


SAMPLING. 


it is tramiiied over to the general ore bins. The sample from the 
first sampling machine drops do\vn to a jaw crnsher, thence to a 
roll feeder and crushing rolls. From these rolls it falls to a second 
automatic sampling machine^ from udiicli one-tenth is removed as a 
final sample, the reject being elevated to tlie second elevator and 
to the rejected ore bins on the second floor. Tlie final sample drops 
down to the set of sampling rolls, thence to the coning floor. In 
order to make the plant entirely automatic throughout from the time 
the ore is fed into the crusher until the final sample lies on the con- 



FIG. 8. AUTOMATIC SAMPIUNG PLANT. 


ing floor, a bucket elevator is used to raise this sample from the 
sampling rolls to a hopper bin over the coning floor, from which it 
is dropped upon the coning floor as required. 

The above is a typical crushing and sampling mill for custom 
gold ores, the main feature being the necessity of recrushing and 
thoroughly mixing the sam])le each time as it comes from a sampling 
machine. This method is necessary in order to obtain accurate sam¬ 
ples of gold ores, especially so for custom Avork. 

In sampling copper ores containing little or no gold or silver 
values, such elaborate sampling machinery is not necessary. 


























































































































































































COLORADO 

IRON WORKS CO 


A SMALL S:\rELTING PLANT. 


23 


A Small Copper Smelting Plant. 

The drawing reproduced below shows a very desirable layout 
for a plant of small size, such as we often supply to mining com¬ 
panies for smelting their own ores. As mentioned elsewhere in this 
book, the ore should be fairly high-grade to make the operation of 
such a plant as this profitable, not for metallurgical reasons, but 
because of the higher relative cost of operating on a small scale. 
However, this will often be more than offset by the saving of high 
transportation charges, if the mine is unfavorably located in this 



respect, and it is a fact that many of the larger smelters of today 
commenced on just such a scale. 

The plant has a hill-side site, the ore being delivered from the 
mine by wagon, into bins placed at such height that the ore is drawn 
from them on the feed floor level. The charges are made up here 
with a minimum of labor for a plant of this size. The power plant 
and blower are placed on the tapping floor level and the slag is dis¬ 
posed of in hand pots. 

The furnace downtake connects with a dust flue, which leads 
to a stack, and there is also a bleeder stack with damper. The dust 
flue is ]flaced on the charging floor level. 

























































































































24 


A HOT BLAST S^IELTING PLANT. 


COLORADO 

IRON WORKS CO 



FIG. 10. HOT BLAST COPPER MATTING PLANT. 


























































































































































































































































































































COLORADO 

RO» WOKKS CO 


A HOT BLAST SMELTING PLANT. 


25 


Hot Blast Copper Matting Plant. 

The plant shown on this and the opposite pages is a compact 
and efficient one for copper matte smelting with hot blast. 

The blast pipe from the blower leads to the LT-pipe hot blast 
stove, after passing through 'which the blast is led to the bustle pipe of 
the furnace. It vdll be noted that the blast main from the blower is 
continued direct to the furnace. This is to enable the furnace to 



FIG. 11. HOT BLAST COPPER MATTING PLANT. 


be run with cold blast, should the stove be temporarily out of service, 
by means of the blast gates provided for that purpose. 

A round, stationary forehearth is showm in which the continu¬ 
ously flowing stream of slag and matte separates, and from which 
the slag overflows and the matte is tapped at inteiuTals. The dust 
chamber is placed, as usual, on the feed floor level for economy in 
handling flue dust, and a platform elevator is shown, for raising 
foul slag, liarrings and other material requiring resmelting to the 
feed floor level for charging into the furnace. 




















































































































































































































20 


A SAIELTING AND CONVERTING PLANT. 


COLORADO 

IRON WORKS CO 



5 


























































































































































































































































COLORADO 

RON WORKS CO 


A S:\rELTINa and converting plant. 


•27 


Copper Matting and Converting Plant. 

The ])lan and elevation here shown illustrate the general ar¬ 
rangement of tlie blast furnace and converter department of a smelt¬ 
ing plant designed with a view to its subsequent convenient enlarge¬ 
ment. 

The ore bins are shown at /i, the cliarge iloor at B, and the tap¬ 
ping floor at C. The tracks for handling the charges and slag are 
shown in the plan, the tracks which serve the furnace and lead to the 
ore bins and dnst chamber E, being on the level above the tracks for 
slag disposal. The furnace is placed on a liench above the converters, 



and the matte is tapped directly from the forehearth into a ladle 
on the converter honse floor I), and charged into the converters by 
the traveling crane. A separate dust chamber for the converters is 
shown at F, and the ])ower plant at G. 

In each end of the converter house is a bay, one for relining and 
one for storage of converter shells. Increase in capacity will be 
secured by extending the furnace and converter buildings longi¬ 
tudinally Riid with this end in view the bltist mam and dust flue aie 
of extra size. The power plant can be added to in the opposite 

direction. 



















































































































28 


HOT BLAST SMELTING. 


COLORADO 

IRON WORKS CO 


Hot Blast Smelting. | 

If the ninount of air blown into a blast furnace were closely S 
watched and regulated to suit varying conditions in the same man¬ 
ner as the coke and constituents of the charge are varied from time ^ 
to time, much better results would in general be accomplished. The 
blast, however, is ordinarily given no attention except in time of || 

emergency, the blowers being usually run at constant speed and the 
solid components of the reaction mixture varied to secure the desired I 
results at constant blast volume. This is not only neglecting a fac- I 
tor susceptible of adjustment but is evidence of a failure to ade- || 
quately appreciate that the air, although intangible and obtained 
without cost, is just as real an ingredient as any of the others which ^ 
react together to bring about the smelting of the ores. 

Every pound of air which is blown into a blast furnace has to 
be heated to the smelting temperature before it escapes. The only 
constituent of the air necessary for the reactions is the oxygen, and 
as the oxygen is only about 23 per cent, of the air by weight, every 
pound of it blown into the furnace is accompanied by over three 
pounds of nitrogen, and this inert gas has also to he heated tO' the 
smelting temperature. 

The magnitude of the heat losses due to heatino’ the nitrogen 
is not readily appreciated without recourse to figures. In an ordi¬ 
nary blast furnace running with cold blast, from a ton and a half ; 
to two tons of air is blown for every ton of charge smelted, the spe¬ 
cific heat of air heine: about .25 while that of the average ores and 
fiuxes is about .20. Thus the quantity of heat required to bring the 
air up to the smelting temperature is twice, or more than twice, the 
amount necessary to smelt the charge. This means that of the total 
heat produced, hut one-third is utilized in smelting the charge, while 
two-thirds is consumed in heating the air. Here, then, is a heat loss 
incomparably greater than any other, but one which can be very 
greatly reduced. It can be done by preheating the blast. 

To the application of hot blast is due the great economy and 
efficiency realized in modern iron smelting practice, for it is the appli¬ 
cation of heated air blast that has made the great iron furnaces of 
today possible. Blown with cold blast not one of them could run a 
week. Heated blast, making uniform conditions of combustion and 
of consequent reactions possible in each individual cross section of 



COLOR ADO 

IRON WORKS CO 


HOT BLAST SMELTING. 


29 


the furnace, lias made high blast pressure possible, without which 
furnaces of large cross sectional area could not be blown. There is 
no condition of blast temperature applying in iron smelting that 
does not apply with equal force and effect in lead smelting for gold 
and silver and in co]iper matting. Localization or distribution of 
lieat, according to conditions demanded by the reactions sought tO' be 
realized, are accomplished by formulating suitable relative propor¬ 
tions of air temperature, pressure and volume, cross section of the 
furnace at the tuyeres and general dimensions, with a certainty and 
regularity not possible in cold-blast smelting. 

The air blast in iron smelting is heated bv the inflammable gases, 
chiefly carbon monoxide, which are evolved. Little or no such gases 
escape from furnaces smelting the ores of copper, lead, silver and 
gold, and hence to heat the air blast for these, other means must be 
resorted to. 

If in any particular zone of the furnace a given condition of 
temperatnre, oxidation of fuel, and incandescence is necessary, then 
that condition is desirable in the whole of that zone. Intense heat 
is a necessary condition of the smelting zone of a furnace. Cold, 
purely as cold in the air blast introduced for the purpose of ]U’o- 
ducing any useful modifying effect on a zone of the furnace where 
incandescence is a. normal and necessary condition, is an absurdity. 
The effect of such cold can only have a retarding and disturbing 
influence in that zone. 

If the current of cold air could be kept constantly impinging 
on the glowing coke, then to overcome its cooling influence would 
he only a question of fuel added ; hut it is not so, because such 
incandescent fuel as a sliaiq) blast of cold air is caused to impinge 
against, is at once cooled—blown out, as it were—and it is only 
after the Iflast of cold air has passed through the lieated mass of 
material, and hecomes heated thereby, that it can strike directly 
upon incandescent fuel without deadening or cooling it. This is 
plainly seen in the operation of any cold-blast furnace, for, on 
looking into the tuveres, thev are generally seen to be black and to 
look cold throughout, except that far in, an occasional bright spot 
may be seen. Such bright spots are always ]irotected from the 
impact of the cold blast l)y the cooled, or partially cooled, material 
at the tuyeres, against which the air im])inges on its entrance to 
the furnace, and thence finds its way around through the heated 




80 


HOT BLAST SMELTING. 


COLORADO 
iron works CO 


mass of furnace material ami becomes itself heated. It is then 
prepared to perform its functions in the necessary reactions. The 
cooling in spots and patches caused by forcing a blast of cold air into 
it, curtails the area and the efficiency of the smelting zone, not only 
in proportion to those abnormally cooled S])ots or jiatches, but fai 
more than this, for they lie there in the way of the blast, oli^tiuct- 
ing and preventing it from circulating freely throughout the incan¬ 
descent zone, which it necessarily should do, for the requisite sup¬ 
ply of oxygen tO' each and every individual incli in that section. 
Xot only is the room that such cooled areas occupy lost absolutely 
and to be deducted from value of cross section, but their adverse 
etfect on the furnace operation, by deflecting the blast upward or 
downward, anywhere aivay from Mdiere it is needed to M'here it is 
not needed, is still more serious, for no possible good, but much 
harm, must come as a result of blast blown against cooled masses of 
furnace material, and deflected thence into material from M’hich 
heat is abstracted bv the cool areas. It is onlv the air that gets 
around these cool spots in some way and into the burning fuel, and 
is then heated, that does effective duty. 

In like manner and for like reasons combustion may be checked 
and the smelting operation ended by a very violent blast of cold 
air in a furnace burning carbonaceous fuel, and it is for this rea¬ 
son that very large furnaces can not be operated Avith cold blast. 
Whenever the furnace is so large that the l)last pressure must be in¬ 
creased to several pounds, in order to penetrate to the center of the 
whole mass of furnace material at the tuvere zone to maintain com- 
bustion there, then the excess of cold extinguishes the fire—blows 
it out, as it ivere—in continually Mudeninff areas in the neii»‘hbor- 
hood of the tuyere^, udiere it is introduced, and for distances in¬ 
ward greater and greater as blast pressure is increased, but only 
in patches or spots until the center is reached and cooled so much 
as to stop the smelting operation all along the center line. The half 
melted mass of unsmelted material cools more and more, aT-o-winp’ 
larger and larger, until it is finally connected here and there with 
the cold patches between the center and the sides, and now excessive 
irregularities are culminating in a frozen-up furnace, often solid at 
the center, while yet partially open along the sides. 

A part of the air sent to a blast furnace is for the purpose of 
generating heat by the huraing of fuel to raise the temperature of 



:OLOR ADO 

RON WORKS CO 


HOT BLAST SMELTING. 


31 


material within the furnace to a point at which it is possible for the 
desired chemical reactions to take place rapidly, and further to 
melt such material when it reaches the tuyere zone; while another 
part is required for its oxidizing effect higher up in the furnace on 
ores carrying sulphniq iron, etc. There are large proportional areas, 
especially in the neighborhood of the tuyeres, in every cold-blast fur¬ 
nace, in which the desired reactions can not take place because the 
blast of cold air keeps these areas too cool to admit of them. Witness 
the cold, dark spots or patches, and often the whole mass of material, 
in the neighborhood of the tuyeres in every cold-hlast furnace. Pro¬ 
portionally as the air is sent hot into the furnace these cool areas 
are reduced in size and in far greater proportion is the capacity and 
efficiency of the furnace increased. Zinc crusts and other accretions 
of kindred nature obtrude less difficulties to combat wdien not com¬ 
plicated by the presence of cold inactive spots produced by the cold 
of the air blast. 

• 

A pound of carbon requires 11.6 pounds of air for its consump¬ 
tion, and conversely for each pound of caiTon that is saved from 
burning in the furnace by burning it in contact wuth the blast before 
it reaches the furnace, the cooling influence of 11.6 pounds of cold 
air is kept out of the zone of intensest heat. 

In cold-blast furnaces there is a constant tendency to burn too 
high up above the tuyere zone, wliich is caused l)y tlie cold air cool¬ 
ing, relatively, all material at the tuyeres, wdiile itself being heated 
up to the temperature at wdiich it is ]>ossible for it to become a fac¬ 
tor in the reactions to wliich it is necessary. 

And so it turns out that in the absence of a heating stove out¬ 
side the blast furnace in which the air Idast inav be heated, the fur- 
nace itself at its most vital and most sensitive part, the tuyere zone, 
must be utilized as a stove for that purpose primarily and at the 
expense of its efficiency for its other duties and functions. 

Hot air is a most potent factor in facility of control in furnace 
workino’. Eliminating the element of cold from the air blast removes 

O O 

the one unmanageable factor in blast furnace smelting. It is un- 
manaa’eal)le because the course or direction of the air wdien it enters 
the furnace is largely determined by the dark areas and patches of 
cold material, rendered so dark and cold by the cold of the air blast 
imjiiuging against it. 


32 


HOT BLAST SMELTING. 


COLORADO 

IRON WORKS CO^ 


An air blast heated to SCO degrees Fahrenheit, on the contrar\, 
does not cause serious local cooling when blown into the tinere zone. 


but causes the coke to glow brighter and burn hotter. Less coke 
is needed there and hence less air to burn it, or, conversely, if as 
much air be blown hot as would be blown cold were the furnace run 
on cold blast, then the smelting capacity wdll be greatly increased. 

Because the blast is heated it does not follow that the furnace 
need be, or would be run hotter than is common or desirable. TTot 
blast does not necessarily involve increased temperature in any one 
zone of the furnace. Tncandescence at the tuyere zone Avhere the 
air blast enters, is a necessary condition of every blast furnace, but 
the temperature of the heated blast being always below that of in¬ 
candescence, the heat of that zone and of the whole furnace is -within 
easA^ and accurate control. 

Assume a furnace -1-2 by 1 68 inches cross section at the tuyeres, 
into Avhich 10,000 cubic feet of cold air is blown per minute, and 
three hundred tons per 21:-hour day of sulphide and other ores, fluxes 
and fuel are charged in, the percentage of good coke being 11 per 
cent, of the charge. 

The 10,000 cubic feet of air Idown in each minute Aveigh 761 
pounds at sea level, Avith normal temperature 62 degrees Fahrenheit. 
Three hundred tons of charge per day of 21: hours is 417 pounds per 
minute; the coke, being 11 per cent, of this, is 45.87 pounds, say 46 
pounds per minute. To burn pure carbon two and tAvo-thirds times 
its Aveight in oxygen is required. Assume 10 ])er cent, off, for ash and 
other Avaste, and there is left 41.4 pounds of carbon, Avhich, multi¬ 
plied by tAvo and two-thirds, giAns 110.4 pounds of oxygen, or 480 
pounds of air, the extreme minimum possible. This, from 761 
pounds of air bloAvn in, leaves 281 pounds of air per minute absorbed 
in burning sul})hur and iron, in other reactions, and some passing ~ 
through the furnace unchanged. An ore charge that has enough 
sulphur in it to run cold blast on 11 per cent, fuel charge Avill always 
run on 3 per cent, and less, Avith 800 degrees Fahrenheit hot blast. 

By calculation as before, but uoav a]iplied to hot blast, 3 per 
cent, of the charge being fuel Avould absorb 131 pounds of air, Avhich, 
added to 281 pounds bloAvn in the cold blast and not accounted for 
as combined Avith carbon, assumed again as excess in the case of 
hot blast, makes a total of air required to drive the hot-blast fur¬ 
nace 412 ponnds, or 5,400 cubic feet of air required in the hot-blast 





COLORADO 

IRON WORKS CO 


JIOT BLAST SMELTING. 


33 


furnace for a given duty, as against 10,000 cubic feet in the cold- 
blast furnace. It is only this smaller quantity, to-wit, 5,400 cubic 
feet of air, that must be heated in the stove for such 2 ,‘iveu dutv, 
and that, with a cheaper fuel, as against ten thousand cubic feet 
to be heated at the tuyere zone of the cold-blast furnace with expen¬ 
sive coke. 

Idle it is true that a less ultimate number of heat units will 
heat a cubic foot of air to a given temperature Avhere the air is ex¬ 
posed to the glowing' fuel, as in the tuyere zone of a l)last furnace, 
than it Avill do tlirough the medium of heated jiipes, as in our U-pipe 
stove, it is also true that any kind of commercial fuel, as coal, 
wood, oil or gas, is suitable for heating the U-pipes of a stoA'e, 
while in the blast furnace only the most ex]iensive fuel, as coke or 
charcoal, can be used, and the heating of the air is there done Avith 
this expensive fuel. 

In a general Avay, Avith the average conditions as they obtain 
throughout the country, Avith lower-])riced fuel ada])ted for heat¬ 
ing air in the U-])i])e stove, as com]>ared Avith the high-priced coke 
that must be used in the blast furnace, air may be heated as cheaply, 
pound for pound, to a temperature of 700 or 800 degrees Fahrenheit 
in a Avell designed stoA'e as in the smelting zone of the blast furnace. 

In the cold blast furnace the cold air is hloAvn in at the tuyere 
zone, and a part of it is there al)sorl)ed in kee])ing u]> the coke hre, 
Avhile the excess over that so used is heated at that point, and jiasses 
thus hot into the zones of the furnace aboA'e, and there contributes the 
necessary oxygen to luirn the sulphur. For this reason most of the 
sulphur is burned high up in the cold-blast furnace instead of l)eing 
burned at the smelting zone, Avhere its calorific effect can he of any 
A'alue in the smelting operation. 

When sul])hur is burned in the higher zones of the furnace, its 
tendency is to carry the smelting zone bodily high up, and AA'hen this 
occurs the furnace soon freezes u]l Burning much sulphur above, 
as must ahvays be done in a cold-blast furnace, contributes to, and 
usually produces, hot top ; and hence cold-hlast furnaces running on 
a high sulphur charge nearly, or quite always run Avith hot top. 

.V cold blast matting furnace, Avith a considerable sulphur con¬ 
tent in the charge, and running Avith a hot top, Avill run hot Hast on 

the same charge Avith a cool top; the calorific value of the sulphur 
2 


irOT BLAST S^rELTING. 


COLORADO 

IRON WORKS CO 


O 


4 


in tlie c'liarii'e will be utilized and that equivalent of beat directly 
saved in coke. 

Jn smelting’ oxides to black co|)per with cold blast, ulieie the 
base is chietlv iron, the fuel required is about 16 per cent, of the 
charge, the percentage of fuel increasing where iron is replaced by 
lime. 

in smelting sulphides containing io to 25 per cent, sulphur in 
the charge, with cold air blast, about 10 j^er cent, h) 11 ]^er cent, of 
the charv’e must be carbonaceous fuel. Thus some of the sulphur 
is burned, saving some coke, the air necessary to burn this sulphur 
beina’ in excess of that necessarv to burn the coke and l)eing heated 
in its ])assage through. 

Idle i^ercentage of sulphur that a charge may carry when smelt¬ 
ing with cold lilast is limited, by reason o! the tenor of the resul¬ 
tant matte running lower and loAver as ])ereentage of sulphur is in¬ 
creased. When much carbon is beiiu>’ burned in the furnace, thus 
ju’oducing much heat, much snl])hur can not be burned, and there¬ 
fore, if a heavy charge of sulphides, they are mostly melted down, 
thus lowering’ the tenor of the matte. It is for this reason that a 
liigh grade matte can not be ])roduced in a cold blast furnace with a 
high sul])hur charge. With the air blast heated to 800 or 000 de¬ 
grees, the heaviest sul])hides are smelted raAv, with 2 or 3 per cent., 
or less, of coke, ])roducing a considerably higher grade matte than 
is possible with the same ore charge in a cold-blast furnace. 

Copper matting is essentially an oxidizing process as to the 
ores being treated, and every pound of carbonaceo\is fuel that it 
is necessary to use in the ])rocess for the purpose of producing heat 
whereby the necessary reactions may take place, is a direct olistacle 
to the realization of the best results in tenor of matte, because in 
burning such fuel much carbon monoxide is ])r()duced, which burns 
at once in the ]U’esence of the necessary heat, robbing FeO or SO 2 or 
air, or all of them, of oxygen, sending the iron of the first to the 
matte to encumber that, instead of allowing it to combine with silica 
to form slag, forming sul])hur from the second and sending the sul¬ 
phur to the matte again to encumber that, reducing its tenor, instead 
of allowing the sul])hur to gO' ofi‘ as sulphurous acid gas, and the third, 
the air, roblung that of oxygen that is needed to combine witli the 
iron and tlu* sul])hur of the ore to dispose of them, the one for the 





COLORADO 

RON WORKS CO 


JACKET WATER VAPORIZATION. 


fJ 


slag as a necessary constituent, the other to the chimney and out of 
the wav. 

There are none of the reactions involved in co])per matting of 
pyritons ores in which carbon is necessary or a desirable factor. 
Its sole office in that class of smelting is the ])rodnction of heat neces¬ 
sary to the operation. It follows that the less of carbonaceous fuel 
that can be burned in the furnace for the production of heat neces¬ 
sary, and the more the snlpluir of tlie ore that can he utilized for 
heat production, the higher grade the matte product will be, other 
conditions being parallel. The utilization of snl])hnr as fuel in¬ 
volves furnace conditions not vitallv necessarv to smeltinp* with car- 
bonaceons fuel, in that the calorific value in heat units in the former 
is innch lower than in the latter. 

The foregoing should make plain how the amount of blast and 
the quantity of coke are interdependent and how heating the Idast 
reduces the coke and redncinv the coke ap’ain reduces tlie blast. 
The net result in ])ractice is a gain of about 50 ])er cent, in tonnage 
smelted, better concentration and greater regularity in operation. 


The Vaporization of Jacket Water. 

(Patented.) 


In many localities the matter of jacket water sn])])ly is a very 
serious one, either from absolute scarcity, expense of ])umping, or 
cost, where it has to he ])urchased. This led us to a serious study 
of the problem, and our solution of it, the Nesmith ])atent system of 
vaporization, not only reduces the amount required to one-eighth of 
that ordinarily necessary, hut also provides what experience has 
proved to be the best method of cooling even where water is alumdant. 

Some smelter operators run so much water through their jackets 


that it is discharged at a temperature much below the boiling ])oint. 
Their reason for this is ])riinarily tO' obviate tlie close attention other¬ 
wise necessary and they also tliiidv that they are on the safe side 
and that the cooler the jackets are run, the better. This is a mis¬ 
taken idea. Aside from the fact that an important loss of heat, 
which must he compensated for by additional fuel, results from such 
])ractice, the life of the jackets is much greater when they are run 
with the discharge as near the l)oiling ])oint as possible. Both cast 


JACKKT WATER VAPORIZATION. 


COLORADO 
IRON WORKS CO 


:U) 


iron and steel have greater tensile strength and a higher elastic limit 
at dtM) degrees Fahrenheit than at lower temperatures, and the 
hotter pickets can he kept, the more durable they will be. More 
cast iron jackets are broken and steel jackets damaged by running 
an excess of cold water through them than in any other way. The 
sudden admission of cold water to a cast iron jacket which has been 
running hot is especially liable to cause its failure. 

As indicated by its title, the princijile upon which this system 
is based is the taking advantage of the latent heat of vaporization 
of water. The magnitude of the saving thus effected is plainly 
apparent in the following figures in which the British thermal unit 
is used, as the Fahrenheit scale of temperature is still the most 
familiar and most commonly used in this country exce])t in high tem¬ 
perature work. 

The heat absorbed by one pound of water at 212 degrees F., 
in jiassing into steam is 9hG units, the application of this amount 
of heat being necessary to ])rodnce the change of state. In cooling 
jackets in the ordinary manner, the heat units carried off by the 
water equal the numher of degrees difference in temperature be¬ 
tween the feed and discharge, and assuming the feed water temper¬ 
ature to he 62 degrees and the discharge 212 degrees, the maximum 
possible heat abstraction of one pound of water is 150 units. 

If, now, the pound of water he completely vaporized, there will 
he 966 units added to the 150 units, or a total of 1,116 units of 
heat utilized. This shows the amount of water necessary when vap¬ 
orized to he, 150 1116 = 0.1344 or 13.44 ]ier cent, of that neces¬ 

sary where the water is discharged at the boiling point. The re¬ 
sults in actual practice are better than this, for the discharge of the 
water at the boiling point has been assumed, and this is a condi¬ 
tion which is never even closely ap])roached, owing to the danger 
of supplying insufficient water. 

The water obviously can not be boiled in the jackets, but our 
system provides means whereby full advantage is taken of the latent 
heat of vaporization without danger of overheating any jacket—in 
fact, with absolute assurance of all jackets being continuously and 
evenly cooled. 

The vaporizing system operates in a manner similar to the hot 
water system ordinarily installed in residences, in which the water 




COLORADO 

IRON WORKS CO 


JACKET WATER VAPORIZATION. 



FIG. 11. NESMITH PATENT JACKET WATER VAPORIZER. 


























































































































































































JACKET WATEK AE\POKIZATION. 


COLORADO 

IRON WORKS CO 


:}8 


back in the range corresponds to the water jackets of the blast fur¬ 
nace. The arrangement of piping is similar and circnlation of the 
water is maintained in the same way. 

For nse with this system the jackets are the same as wdth the 
ordinary overflow system except that the pipe connections are larger 
in order to reduce friction. The pipes lead to a closed drum sur¬ 
rounding the furnace, the feed pipes being connected to the bottom 
and the discharge pipes entering the drum slightly below the water 
level. The tendency of the hot water to rise and cold ^vater to And 
the lowest level maintains a very effective circnlation and any boil¬ 
ing takes place in the drum, not in the jackets, because the water in 
the jackets is under snflicient head to cause the boiling joint to be 
several degrees higher than in the drum which is only under atmos¬ 
pheric pressure. A gauge glass indicates the water level, an auto¬ 
matic float valve controls the admission of water to replace that 
evaporated, and a vapor esca])e ])ipe provided wdth an exhaust head 
conducts the steam formed to the atmosphere. 

A smelter superintendent, after operating a furnace provided 
with onr vc])orization system for several months, wrote ns recently 
as follows in re]dy to a request from ns for information as to jacket 
water consumption: 

he furnace ])roper is using about 90 gallons per hour. I 
have not had time to figure this back to gallons per square foot of 
jacket area, Imt as the jacket area on this furnace is large, it should 
shoAv a very low water consumption ]ier square foot. * * * p 

think you are overlooking a bet in not pushing it, as it is without 
question the best water system for a blast furnace I have ever seen. 
All jackets are always at a uniform temperature; wdth a proper 
float valve absolutely no attention is required. In blowing-in we 
never think of the Avater, Avhile Avitli the old style OA^erfloAV system it 
generally keeps one man busy to keep from burning a jacket. In 
places Avhere Avater is scarce a more elaborate c(mdenser on the ex¬ 
haust head Avould save nearlv all the Avater. Another verv o-ood 

* t O 

feature is the fact that different furnace men have their oavu ideas 
about jacket Avater —one Avants to run his Avater cool or cold and 
another hot Avith no tAvo jackets the same, Avhile Avith this svstem it 
absolutely cuts out the ^]>ersonal element’ and the jackets must have 
a decided benefit from the constant temperature.” 


COLORADO 

IRON WORKS CO 


JACKET WATER VAPORIZATION. 


39 


Jacket water coiisiiiin)tioii is usually deteriiiiiied in gallons per 
minute, to avoid large tigiires, but as is evident from the above 
quotation, gallons })er hour would be a more convenient measure of 
comparison were the vaporizer system in universal use. However, 
on the customary basis, the exposed jacketed surface of the above 
furnace being did square feet, the water (‘onsuniption was 0.00362 
gallons per minute per square foot of jacket area. This was a copper 
matting furnace. Another user of the vaporizer system, operating a 
lead furnace, reported a water cousum])tion of 0.0113 gallons per 
minute jier square foot jacket area, but tliis vaporizer was run with¬ 
out an automatic float valve and loss of some water was consequently 
unavoidable. 

(l)m])arison of the al)Ove with })ublished figures for Cananea, 
0.616, ami for Granbv, 0.31 shows an actual saving far above the 
theoretical, and brings out strongly the magnitude of the waste of 
water in cooling jackets in the ordinary wav. At Granliv, the dis- 
charge from the upper jackets was the feed for the lower jackets, 
which accounts for the large economv shown over Cananea, the 
amount of water used at Cananea being about what is ordinarily 
required. 

The jacket water is commonly run into settling ])onds where it 
is cooled and reused, but there is great loss from evaporation and 
seejiage, to say nothing of the expense of ])uniping. The installa¬ 
tion of tlie va])orizing system will cost less than settling ]ionds and 
it entails no continual ex])ense, as for ])umping. In addition, it 
provides cooling means in every way su])erior to the ordinary over¬ 
flow method. 

We liave always arranged the piping of our vaporization sys¬ 
tem so that tlie jackets could l)e fed in the ordinary manner when 
blowing-in the furnace, and do not intend to depart from this prac¬ 
tice although the letter above quoted would indicate that we might 
safely do so. 


40 


DATA FOR ESTIMATING. 


COLORADO 

IRON WORKS CO 


Data Required for Estimates. 


As smelting consists in subjecting an ore or mixture of ores 
containing slag-forming constituents in ])ro]ier pro})ortions, to snch 
conditions of temjieratiire and oxidation or reduction as will cause 
the formation of a proper slag, and as chemical analysis furnishes 
the means for ascertaining the composition of the ores and llnxes 
})reparatory to determining the jiroportions in which tliey may be 
mixed to form a suitable charge, it is a simple matter for a compe¬ 
tent metallnrgist to determine the applicability of the smelting pro¬ 
cess to any particular ore if he is provided with analyses of the ore 
and available llnxes. Further than this, he can closely ap])roximate 
the cost per ton for smelting, and from this the prol)able profit or 
loss from the o])eration within quite narrow limits. 

In view of these facts, there is no excuse for installing a smelt¬ 


ing plant for the treatment of ores nnsnitable for the smelting 
method. The possibility of smelting a given ore can l)e predicted 
Avith greater certainty than can the possibility of treating it by any 
other ore treatment method. 

Some ores are self-llnxing, that is, contain slag-forming con¬ 
stituents in snch proportions that they Avill produce a flnid slag, bnt 
such ores are nncommon. Usually the ore is deficient in one or more 
of the necessary elements, and llnxes containing an excess of such 
element or elements must l)e added to it. Often it is possible to 
secure a flux at Ioav cost, Avhich, Avhile it Avould not pay to smelt 
l)y itself, contains enough A^alnes to about pay its way through the 
furnace, bnt Avhen it is necessary to add large quantities of barren 
fluxes the disadvantage is great, as the cost of smelting a ton of ore 
is the cost of smelting the ton of ore and the fluxes added to it. 

The most common constituents of ores Avhich are important 
from a smelting stand])oint are silica, iron, lime, alnmina, zinc, sul¬ 
phur, arsenic, manganese, and magnesia. Other elements may be 
present in sufficient quantity to require consideration; thus fluorine, 
if in combination with lime, renders the lime unavailable as a flux, 
and large quantities of barium are sometimes troublesome. Copper 
or lead is necessary, either as the valuable constituent of the smeltine: 
charge, or as a collector of precious metals. Gold and silver are of 
no importance whatever in determining the amenability of an ore 
to smelting, lait if present, they are of course important in their 
bearing on the financial results. 


Much lead, Avhen gold and silver are ]')resent, is very objection¬ 
able in copper matte smelting, as the lead is lost and precious metal 


COLORADO 

IRON WORKS CO 


41 


DATA FOR ESTI^rATIN^T. 

with it. Some copper, on the contrary, is desirable in smelting ores 
to lead base bullion, as it })ermits higher snlphnr than would other¬ 
wise be ]) 0 ssible, forming a copper-iron-lead matte, which also pro¬ 
motes the making of clean slags. 

The analysis npon which to determine the suitability of ores 
for smelting slionld show, not only copper, lead, silica, iron, lime and 
snlphnr, hnt, as certain other elements may be present in undesir¬ 
able quantity, the analysis should total at least 97 per cent. This 
total will show few constitnents in clean ores hnt will be made up 
by a greater nnmher if the ore is a complex one. The effect of 
flourine on the availability of lime points to the necessity of care 
and completeness in the analysis, and it may also he mentioned here 
that alnmina and zinc, when ]wesent together, are more difficnlt to 
contend with than either alone. 

As in most processes of ore treatment, or other enterprises for 
that matter, the cost becomes reduced as the scale of operations is 
increased. In smelting, however, there is a lower limit of capacity 
beyond Avhich it is impossible to go by reason of the difficnlty of 
maintaining small blast furnaces in continuous operation. In lead 
smelting this may l)e taken at about 20 tons per day and in copper 
matting at about 30 tons ])er day. Even at these capacities, the ore 
mixture should be an easily smelted one for metallurgical reasons, 
and a rich one for financial reasons. These small furnaces often 
pay well in smelting high-grade ores at isolated properties. 

The size furnace necessary for any given capacity can not be 
stated Avithout a knoAvledge of the ore to he smelted. To do justice 
to the purchaser, his problem must be considered in all its phases 
and the equipment must l)e designed and constructed to meet the 
requirements of his ]Aarticular case. This being so, it is manifestly 
futile to attempt a tabulation of furnace capacities and positiAnly 
misleading to publish figures alleged to cover the ]wice of equipment 
or cost of operating, as is frequently done by irresponsible parties. 

We are ]ffeased at all times to advise regarding the practicabil¬ 
ity of smelting any particular ores and to prepare estimates coAnr- 
ing suitalde equipment. As aboAn indicated Ave Avill require an 
anah’sis of each of the ores and fluxes, and these analyses should not 
be made on random samples, but on samples from a systematic 
sanpding of the deposits, so that they Avill as nearly as possilfie he 
truly representative of the run of ore Avhich Avill come to the furnace 
Avhen in operation. 

If estimates on the cost of operation are desired, Ave should also 
liaA^e full details as to cost of coke, labor, etc. 


42 


BLAST FURXACE DETAILS. 


COLORADO 

IRON WORKS CO 


The Blast Furnace Structure. 

We have not attained onr enviable position as builders of the 
most perfect smelting eqni])ment without having overcome all of the 
mechanical dithcnlties which have devxdoped during the advance¬ 
ment which has been made in blast furnace smelting. The modern 
blast furnace as we bnild it is a very ethcient apparatus and every 
detail has been perfected in snch a manner that purchasers may rest 
assured that they Avill be free from petty annoyances arising in 
operation, due to insnfhcient attention to details. 





FIG. 15. COPPER FURNACES ERECTED AT COLORADO IRON WORKS. 

Many of the most important adyancements which haye been 
made ha\e originated with ns and since come into general nse, and 
while we always aim to be in the forefront as builders of smelting- 
equipment and to produce apparatus of the most advanced tyite, we 
are always conservative in adopting innovations and intending pur¬ 
chasers may have the fullest confidence that they are not experi- 
menting Avhen buying of ns. 

V o have no “standard” furnaces, that is, no “stock” furnaces. 
Each is especially designed and built for the conditions under which 








COLORADO 

IRON WORKS CO 


r.LAST FrFJXACE DETAILS. 


43 


it is intended to ot)erate and ean be relied upon fur the best nietal- 
Inrgieal results. Onr sineltino- e(|ni])nient is very massive, as ve 
early discovered the necessity of putting great weight into it for 
the reason that ordinary calculations for strength do not apply where 
the material is sid)jected to all manner of strains by sudden temper¬ 


ature changes. 


J^very furnace which we bnihl is completely set n]i in onr shop 
and all parts are ]>lainly marked so that there is no dilficnltv in 
erecting the furnace at destination. All the furnaces illustrated in 



FIG. 16. LEAD FURNACES ERECTED AT COLORADO IRON WORKS. 


this catalogue were built by ns. We could show many more, but 
only include those which are necessary to bring out some special 
features. 

It is im])ossil)le here to show all the details entering into the 
modern blast furnace, interesting though it might be to do so; we 
direct s})ecial attention, however, to a few features of si)ecial merit. 
In this connection it is proper to say that we are fully pre[)ared to 
build furnaces to anv desi<>n that mav be fnrnishe<l ns, and that 
we are in no sense contined to onr own ideas as to designs nor to 









44 


BLAST FURNACE DETAILS. 


COLORADO 

IRON WORKS CO 


those ill general use. It is very coiiiiiion fur changes to be made in 
existing designs or entire new plans to be furnished us to build fur-* 
naces by, to conform to the ideas of customers. We are always glad 
to execute such orders, as we have ever been, for improvements are 
often thus introduced, and it is our desire always to be in the first 
rank in the march of im])rovenient. 

The bosh of a blast furnace has long since been demonstrated 
to be an important feature in its bearing on the smelting operation, 
and that it is essential to economical and efficient work in both lead 
and copper furnaces is generally acknowledged. While smelting is 
possible in blast furnaces having no bosh, there are few, if any, 
cases where a ]iroperly designed bosh would not greatly improve the 
results, and it may fairly be said that where smelting is carried on 
in such a furnace, success is attained in spite of the absence of that 
important feature. 



and consequently higher iqi in tlie 


.V furnace with straight walls 
is indicated for simple melting 
operations, such as melting 
down iron in a foundry cupola ; 
but in smelting, in addition to 
melting, a series of chemical re¬ 
actions must be ])rought about, 
the grouping or form of combi¬ 
nation between the constituents 
of the charge must be changed, 
and bosh is important in facil¬ 
itating these reactions. The re¬ 
actions, so far as concerns re¬ 
duction or oxidation, carbon 
monoxide being the principal 
agent of the former and oxvgen 
of the latter, take place at a 
lower temperature than that 
necessary for slag formation, 
shaft. 


Time is a factor in bringing the reactions to completion, and bo: 
mg tlie furnace ]u-ovides the means of properly proportioning the tii 
during which the charge is subjected to the different conditions existi 
in tlie shaft from feed floor to hearth. As the upper parts of a bosh 































COLOR ADO 

IRON WORKS CO 


BLAST FUKNACE DETAILS. 


■ 45 


furnace have a greater area than the tuyere zone, the charge, in ])ass- 
ing down the shaft, moves more slowly in the upper regions than 
when in the vicinity of the fusion zone and a proper interior contour 
can thus accomplish by time of exposure, reactions which can not 


be accelerated. 



FIG. 18. COPPER FURNACE. 

Straight 

o 

for the rising 
iug against 
rounded hy 
more even permeation 
In a furnace with 
nace material rests j m 
friction as it melts away 
melted mass at and near 


Bosh acts favorably as to the 
time element, both with respect 
to the ore moving down the shaft 
and the air passing up through 
it. At a tem])eratnre of about 
2100 degrees Fahrenheit, the air 
and evolved gases have expanded 
to more than five times their vol¬ 
ume at ordinary temperature, 
and would consequently have to 
])ass up a straight shaft with 
live times the velocity of an 
equal weight of cold gases. As 
it is desirable to exhaust the 
gases of their contained carbon 
monoxide or oxvgeu, as the case 
mav he, as well as their heat, 
before allowing them to escape, 
anything which Avill reduce their 
velocity Avill enable such use of 
the gases to be increased. Fur¬ 
ther advantages connected Avith 
the blast Avhich are secured by 
the bosh, are the production of 
less flue dust and the holding 
of the reactions lower doAvn in 
the furnace. 


Avails Avithiu a furnace offer an easy ])ath of escape 
gases, as the coarse lumps of the charge, Avhere rest- 
he Avails, present greater interstices than Avhere sur- 
ine materml. Bosh breaks this easy patli and causes a 
of the charge hv the gases. 

straight Avails the Avhole Aveight of all fur- 
the bottom, sliding smoothly doAvn Avith little 
at the tuyeres, and the softened, half- 
the tuyeres packs tightly, tending to oh- 












































41 *. 


BLAST FLBXACP: DETAILS. 


COLORADO 

IRON WORKS CO 


Struct the circulation of the air blast. Jn a furnace with boshed 
walls the boshes take the weight of that ])art outside of the vertical 
lines np from the hearth and hence cause fidction on the column of 
ore within itself remote* from the walls directly above the hearth, re- 
ducino' the weight of the ore column on the hearth and at the same 


time causing the ore to kee]) turuing over and working within its 
mass, l.reaking np any aggregation of sintered material that may 
have formed above, and strongly counteracting the tendency to pack 
toa-ether bv reason of the tines hllina all interstices, and to become 
impermeable to the gases on their passage n])ward. 

In this connection we show the interior contour of two l)last 
furnaces, one for lead ores and one for co])])er matte smelting. 
Xeither of these is extreme; on the contrary, they represent stand¬ 
ard practice, and their introdiK'iion here will show the ditferent 
lines along which the develo])ment of the ])rinciple of boshing the 
walls has ])roceeded. These illustrations bring out the main ])oints 
of difference between the lead furnace and the copper furnace, the 

f 

former having a single tier of jackets of comparatively small height, 
with brick shaft above and crucible l)elow, and the latter having 
jackets extending from the cast iron bottom ])late to the inclined 
feed plates at tlie feed floor level. The absolute dimensions of the 
ditferent parts of the shaft are varied to suit the particular work 
for whicli the furnace is designed, and in this our long ex])erience 
has given us special ability. 

Although all jackets are best wlieu made of steel plate, in silver- 
lead furnaces the water jackets are often made of cast iron in sec¬ 
tions about four and a half feet high, and eighteen or twentv inches 


wide. Of such sizes cast iron jackets can be made to stand as well 
and last as long as those made of steel plate; and of such sizes jacket 
sections can be replaced, when necessary, in half an hour, without 
Idowing- out the furnace. 

The annexed illustrations, figure lb, show our improved form 
of curved corner cast iron end jackets and indicate the manner in 
wliich they form the round corners of the furnace in the bosh. 

The jacket shown is for a small furnace, and we also show in 
tliis cut how an end tuyere opening is provided. The wider fur¬ 
naces have the corner jackets made in the same manner but an end 
center jacket is used. The side jackets are all straight on their 
edges. The end jackets curve around the corners in the bosh and 


COLORADO 

IRON WORKS CO 


BLAST FURNACE DETAILS. 


47 


come to straight lines where they meet at the sides. Corner jackets 
made in this form are as durable as side jackets which is not the case 
with square corner jackets liaAong sharp angles in them to conform to 
the bosh of the sides. Those with sharp angles where they widen 
out, are mnch more likelv to crack tlian when made with curves, as 
we have been making them for several years. 

O t 

this ini])rovenient a niinimnm nmnher of jacket jiatterns 
is required for a furnace of any dimensions and the nnnd)er of spare 
jackets necessary to he kept on hand is reduced. 




FIG. 19. IMPROVED FORM OF CAST IRON CORNER JACKETS. 

An important feature of all onr blast furnaces is onr automatic 
gas escape valve. When the blower stops there is danger of com¬ 
bustible gas (CO) rising through the Idow pipes and tilling them 
and the hustle pipe Avith an explosive mixture which is liable to 
ignite from the furnace when the blower starts u]) again. Very seri¬ 
ous explosions have resulted from this cause. 

Valves have been })laced in the pipes or on the hacks of the 
jackets, hut such valves are ahvays unsafe, as they are designed to 
close Avhen the blast stops and are never tight enough to perform 
their function properly. We devised the only automatic gas escape 









































































































COLOR ADO 

48 BLAST FURNACE DETAILS. jron works co 

valve which affords ahsohite iinimmitj from gas explosions and 
])lace it on the hustle pi])e of every furnace. Jt consists of a valve 
of large area Avliich is normally open, but which closes by the pres¬ 
sure of the air when the blast is put on. Being at the highest point, 
the comlmstihle gas, Avhich is lighter than air, has a free means of 
esca})e into the atmosphere. 

In onr lead furnaces onr patented steel arch bar girders now 
take the ])lace of the old style mantel ]Alates and of the later Bheani 


FIG. 20. PATENT STEEL ARCH BAR MANTEL SYSTEM. 

mantels, both of Avhich styles had serious objections in that it was 
not possible to protect them from destruction by the furnace lining 
burning aAvay and exposing them to intense heat. In this system, 
the red brick Avails are carried Avholly by the arch bars, and inside 
them come angle bars and plates under the fire-brick lining of the 
furnace. When the lining burns thin, these plates on the angle 
liars Avill heat and may spring someAvhat, but as they are entirely 
independent of the main girders that carry the Avails, no damage is 
done to the main structure and all there is to be done is to reneAV the 
lining AAdiere it has burned out, AAdiich is usually but for a short dis¬ 
tance aboA^e the jackets. With the old style cast iron mantel plates 










COLORADO 

IRON WORKS CO 


BLAST FUENACE DETAILS. 


49 


carrying the main brick walls of the furnace, and which had to be wide 
enongh to also carry the fire-brick lining, there was always the cer- 
taint^ that when the fire-hrick lining was allowed to burn too thin, 
the inner edge of the wide mantel wonld heat and spring, cracking 
~itte in*^ the main walls, and wonld often itself break, in¬ 
volving thns the not inconsiderable cost and delay of repair to 
walls and replacement with a new mantel. T-heam mantels are sid)- 
ject to the same difficnlty, and being deeper vertically than the cast- 



FIG. 21. PATENT WATER-JACKETED STEEL GIRDER SYSTEM. 


iron mantels the trouble is aggravated. We have applied the arch 
bar system of mantels in most of the silver-lead smelting furnaces 
that we have built during several years, and not one in that time 
has given the slightest trouble or ever will. In some we have in¬ 
troduced water jacket girders, carried hj the main corner columns 
of the furnace. These water girders take the ])lace of the auxiliary 
upper jackets often required above the main jackets, and support 
the furnace lining instead of allowing it to rest on the main jackets 
as is the case where the ordinary auxiliary jackets are used, or in¬ 
stead of being suspended from above by a framework as is sometimes 
done. 













50 


FIG. 22. IMPROVED BLAST FURNACE TUYERE. 

The latest type of our improved cast iron tuyere for blast fur¬ 
naces is shown in Fig. 22. An air-tight gate is built into this tuyere 
so that the air blast to each one can be regulated independently of the 
others. The peep-hole nipple is taper-fitted to the cap so that it 
can be instantly removed for l)arring into the furnace and the cap 
is fastened to the body by an interrupted screw so that it also may 
1)0 easily removed, giving access to the entire interior of the tuyere 



BLAST FUENACE DETAILS. 


COLORADO 

IRON WORKS CO 



FIG. 23. BLAST FURNACE TUYERE. 

when necessary. The slag escape is made very much larger than 
shoAvn in the illustration and the tuyere, as a Avhole, has given the 
greatest satisfaction. It is an improvement over our earlier form 
A , OA\ n I n Fig. 23, and ai’oids the excessive friction of 
the air in the latter OAving to the more favorable angle of the blast 
inlet. This type of tuyere is also used on our hot-blast copper- 
matting furnaces, Avhere the blast is heated to not exceeding 1,000 
degrees, Fahrenheit. 



COLORADO 

IRON WORKS CO 


BLAST FURNACE UETATT.S. 


51 



In Fig. 21: we show the type of tuyere which we use ou fur¬ 
naces where the blow pipes are made of standard pipe and individual 
quick-opening valves are ])laced close nnder the hustle ])ipe. It is 
shown on a nuinher of furnaces illustrated in this hook and has all 
the advantages of the tnvere shown in Fig. 22, with the added one 
that when the tnyere is removed the valve is still in ])osition to shut 
off the blast. 



Fiff. 25 shows our standard tnvere for lead furnaces. The 
jacket has a faced recess, an air-tight connection Iteing made with 
asbestos packing. With this tuyere the opening in the jacket can 
be bushed if necessary, which is not the case with tuyeres projecting 
into the opening. 

















































52 


BLAST FUENACE DETAILS. 


COLOR ADO 

IRON WORKS CO 


The combination fnrnace trainspont shown in Fig. 20 is tlie 
outcome of many years’ study and experience, and is the resnlt of 
continued efforts to ])rodnce one that would give satisfaction. 

It is constrncted of ribbed cast iron plates, liolted together and 
lined on the inside with magnesite brick. To tlie outer end is fitted 
a water-jacketed ti]) made of nearly ])nre co])per, over which the 



FIG. 26. GROSS PATENT TRAP SPOUT. 


liquid slag and matte flow to the settler, this tip taking the most 
severe cutting effect of the matte. The ti]i has a vertical adjust¬ 
ment of about six inches, for the purpose of easily changing the 
amount of trap. 

The success of this spout has been thoroughly demonstrated, 
and we offer it to those having difficulties with their present ones 
as a simple, efficient and inexpensive fnrnace trap-spont for copper 
mattino’ blast fnrnacs. 

O 





COLORADO 

IRON WORKS CO 


LEAD BLAST FURNACES. 


5.3 


Silver-Lead Blast Furnaces. 

The rectangular blast furnace adapted to suieltiug lead ores, 
eitlier alone or with dry ores, is designed along the lines of the 
drawing reproduced on this ])age. Onr wide experience obtained 
in hnilding the great niajority of the lead blast furnaces in oyiera- 




FIG. 27. RECTANGULAR SILVER-LEAD BLAST FURNACE. 


tion in the ITiited States and IMexico has served to equip us with 
the necessary knowledge to vary the design in minor ])articulars 
so as to secure the best results in operation under any given condi¬ 
tions. The duty of lilast furnaces is more severe than other equip¬ 
ment and our success in building furnaces which prove equal to the 
mechanical strains to Avhich they are subjected has contributed to 
onr supremacy no less than onr ability to design them along lines 
which are metallurgically correct. 

























































































































































































































54 


LEAD LEAST FUKNACES. 


COLORADO 

IRON WORKS CO 


J>oacl fiiniacos are built with either steel or cast iron jackets. 
We have developed cast iron jackets to such a ])oint that they give 
really etlicient service, especially so in view of their low cost, but 
steel jackets are Ixdter. There is a limit to the height which a 
jacket may he made when of cast iron, and this is not met Avith in 
the case of steel; furthermore, the steel jackets may he made wider 
and the water connections thereby simplified. e have bnilt lead 
furnaces with cast iron lower and steel upper jackets, hut usually 



build them with a single tier of steel jackets Avhere jackets of consid¬ 
erable height are desirable. The proper interior contour can in this 
case he easily secured. 

On this page we show a plan of the crucible construction used 
in our large lead furnaces. The internal pressure is taken up by 
heavy, ribbed cast iron end plates connected by heavy bolts with 
side plates of steel reinforced with four heavy I-beams. The bolts 
]:)ass through the corners of the brick-work, and curved corner plates 
bolted through slotted holes to the sides and ends complete the curb 
and permit the easing up of the main bolts to allow for expansion of 
the brick-work. The caissons of smaller furnaces are made of heavv 
cast iron plates or steel plates reinforced with T-rail as the case 
demands. 

I lie caisson ])lates rest u])on a bottom formed of steel plates 
wliich prevents the seepage of values into the foundation. 



































































































































































































( 


COLORADO 

IRON WORKS CO LEAD BLAST FURNACES. 55 


Silver-Lead Blast Furnace. 

lliis furnace is most highly recommended where a small capacity 
IS desiied. The rectangular form is superior to the circular or polyg¬ 
onal, and, in addition, this furnace has been designed with special 
lefeience to facility in cleaning out, a feature of great importance 
in so small a unit. 

d he jackets are of flange steel plate and are suspended hy chains 
fioiii the mantel frame, ]ierniitting them to he swung out with less 




1 

FIG 29. SMALL RECTANGULAR LEAD FURNACE. 


difficulty than would be exjierienced in their complete remoyal. The 
blast and water piping haye been so disposed as to render this easy. 

The crucible is built within a caisson of cast iron plates and 
is normally held upward against the bottoms of the jackets by jack 
screws. A car is ])rovided to receiye the crucible when lowered and 
remoye it to be cleaned out or reliued as necessary. Two crucibles 
with cars are furnished so that Avith one in reserye the furnace can 
be cleaned out and started up again AAutli a minimum loss of time. 

The illustration shows the jackets as made for mule-back trans- 
])ortation. For ordinary conditions, the side and end jackets are 
each in one ])iece. 































































































































































































































56 


LEAD BLAST EUBNACES. 


COLORADO 

IRON WORKS CO 


Silver-Lead Blast Furnace. 


The construction illustrated on this page is the best for small 
round furnaces, as the jackets being made in vertical sections render 
it ])ossible to secure the best interior contour. 



FIG. 30. POLYGONAL T.EAD BLAST FURNACE. 


The curb is of heavy steel plate rolled to a circle and rests on 
a bottom ]date which prevents the see])age of metal into the foun¬ 
dation. The brick shaft is circular in section and is carried by a 
cast iron mantel ring resting on the four columns. The hood is 
adapted to be raised for charging and barring, the stack telescoping 
as this is done. We build 86-inch heptagonal and 42-inch octagonal 
furnaces of this design. 






































































































































COLORADO 

IRON WORKS CO 


LEAD BLAST FURNACES. 


K h' 

5 i 


Silver-Lead Blast Furnace. 

I he advantage of a furnace built as here shown, is that the 
division of the jacket vertically into halves enables all seams to be 
flanged outward so that no rivets are exposed on the fire side. The 



jacket can also be easily removed when necessary, which is a con¬ 
venience not obtainable with the jacket bnilt in one piece. 

Jt is inferior to our polygonal furnaces in that it has a straight 
bosh, but by reason of its simpler design and greater facility of 
construction it can be sold at a lower price. 







































































58 


LEAD BT>AST EITKNACES. 


COLORADO 

IRON WORKS CO 


Silver-Lead Blast Furnace. 

The illustration on this page is reproduced from a photograph 
of one of three furnaces supplied at intervals to a large lead smelter. 
It is typical of the best design and construction in large lead furnaces 
with cast iron jackets. 

The curb of the crucible is constructed with very heavVj ribbed 



FIG. 32. 42" X 126" SILVER-LEAD BLAST FURNACE. 

cast iron end plates, and side plates of heavy steel plate reinforced 
with I-beams as shown in the ])lan, Tig. 28. The engraving shows 
part of the brick shaft and the manner in which it is carried on 
our })atent arch-bar mantels, as well as the way the brickwork is 
bound together. 

The automatic gas escape valve which we place on all furnaces 
is shown on the bustle pi])e at its point of connection to the blast 


mam. 


It ^ 



















COLORADO 

IRON WORKS CO LEAIJ BLAST FURNACES. 50 


Silver-Lead Blast Furnace. 

Ihe furnace here illnstrated is one of a number built bv us and 

•j 

embodies a special means of binding the jackets. This consists of 
an I-beam frame carried around the furnace outside of the columns, 
with small jack screws between this frame and the backs of the 
jackets. itb this constimction a jacket can be removed without 
taking down the binder frame and without Aveakening the support 
of the jackets remaining in place. 

The caisson is formed of steel ])lates reinforced Avitb T-rail, 


FIG. 33. 36" X 144" SILVER-LEAD BLAST FURNACE. 

the side plates being rolled to a large radius. The mantel frame 
is formed of I-beams carried on the corner columns, with skew backs 
to take the thrust of an arch sprung over the mantels and transferring 
the Aveigbt of the brick shaft to the corner columns. Many furnaces 
are built this Avay, but Ave recommend our patent arch bar mantel 

construction as superior, for the reasons brought out in the descrip- 

* 

tion of that feature. 














lj:ad blast fuknaces. 


COLORADO 

IRON WORKS CO 


r>o 


Silver-Lead Blast Furnace. 

We here show a silver-lead blast furnace, three of which were 
built for a large western lead smelter. The jackets are of cast iron 
with our regular lead furnace tuyeres and canvas blow pipes, as is 
usual in furnaces of this type. 



FIG. 34. 36" X 144" SILVER-LEAD BLAST FURNACE. 


Our patent arch-bar mantels are shown on the sides of this fur¬ 
nace and cast iron mantels at the ends. We recommend the arch-bar 
mantels for both sides and ends as they have overcome the objections 
to all other forms. 

The crucible construction is such as we have used to a jrreat 
extent—steel plates reinforced with T-rail, the side plates being rolled 
to a curve of large radius. 










LEAD BLAST FUK^S^ACES. 


61 


COLORADO 

IRON WORKS CO 


Silver-Lead Blast Furnace. 

This furnace has cast iron water jackets and our standard 
tuyeres, and is equipped with the N^esmith patent jacket water vapor¬ 
izer described elsewhere in this catalogue, and which reduces the 
amount of water required to less than one-eighth that ordinarily 



necessary. The bustle pipe is combined with the vaporizer drum 
wliereby the blast is warmed and water cooled by exchange of heat. 

The crucible is built within a caisson formed of heavily ribbed 
cast iron plates on both sides and ends, with steel corner plates bolted 
to them through slotted holes, allowing for expansion. Heavy bolts 
})assing through the corners of the crucible take the strain, and a 
plate steel bottom prevents the foundation from becoming impreg¬ 
nated with lead and locking up values. 





















LEAD BLAST FURNACES. 


COLORADO 

IRON WORKS CO 


r>2 


Silver-Lead Blast Furnace. 

The furnace here shown is an example of our small lectangulai 
type. The jackets are of cast iron made in the special manner devel¬ 
oped by uSj although we will build such furnaces with steel jackets if 
desired. This furnace has an end center jacket between the corner 
jackets, provided with a tuyere opening. This tuyere opening is 
pluc'ged on the end where the tap hole is located, and the otlier end 



FIG. 36. 36"x72" SILVER-LEAD BLAST FURNACE. 


tuyere may likewise be closed if it is found unnecessary as is some¬ 
times the case in practice. 

This furnace has our patent arch-bar mantels on sides and 
ends so that all the weight of the brick shaft is transferred through 
these arches to the corner columns. The crucible caisson is made 
of heavy steel plate, reinforced with T-rail, ends straight and sides 
curved to a large radius. 













COLOR ADO 

IRON WORKS CO 


LEAD BLAST rLBXAC'ES. 


63 


Silver-Lead Blast Furnace. 

lliis is an example of our small lead blast furnaces of recent 
design, llie jackets are of cast iron, the corner jackets also forming 
the end. llie end tuyere opening is half in each section, and both 
ends of the furnace have tuyere openings, so that a corner jacket 
will lit in either end of the furnace. 



FIG. 37. 36"x60" SILVER-LEAD BLAST FimNACE. 


Our patent arch-bar mantel frame is shown on this furnace. 
The steel channel curved, and extending between the skew backs 
carries the brick shaft, and the short pieces of angle iron extending 
inward and fastened to the stay rods carry the fire brick lining. 

The caisson plates are of cast iron made very heavy and a plate 
steel bottom prevents seepage of values into the foundation. 










04 


l.EAT) r>LAST FEKNACES. 


COLOR ADO\ 

IRON WORKS CO 



Silver-Lead Blast Furnace. 

For small ('a])aeities, a small reetan 2 ;ular furnace is superior to 
a round one, and we recommend the rectaniJii^l^^' furnace notwith¬ 
standing the fact that the erected cost is somewdiat 2 ;reater by leason 
of the brick shaft and snperstrnctnre. The furnace here showm is 
of as inexpensive constrnction as possible, without sacrificing either 
material or workmanship, and is a good one to smelt the product of 


FIG. 38. 36"x51" SIUVER-LEAD BLAST FURNACE. ] 

] 

1 

a small mine, where it is desired to have the outlay as small as 
possible. 

This furnace has the ordinary I-beam mantel frame carried 
upon the four corner columns wuth skew backs from w'hich relieving 
arches are sprung. The crucible is surrounded by a curb of heavy 
steel plate conforming in shape to the furnace and wdth rounded 


corners. 

















COLOR ADO 

IRON WORKS CO 


LEAD J5LA8T FUKALVCKR. 


05 


Silver-Lead Blast Furnace. 


1 he fiirnaee shown on this page is sectionalized for mnle-baok 
transportation, no single part weighing over 800 pounds. To meet 
the requirements as to maxinmm weight of parts, the jackets ^vere 
made in seetions twelve inches Avide, the furnace thns comprising 
fourteen jackets. 

I he interior contour of this furnace is tlie same as onr laro’cr 



FIG. 39. 30" X 36" SECTIONALIZED LEAD FURNACE. 


rectangular furnaces and it is in every Avay suitable for producing 
metallurgical results e(pial to any furnace of its size, and Avhen ereeted 
the only disadvantage over a similar furnace not sectionalized is the 
more niimerons Avater connections. 

The curb of the crncible is in sections ready to be bolted together, 
tlie bed plate being slii])])ed in lialves to be riveted together on the 
ground. The furnace Avas built Avith onr patent arch-bar mantel 
frame, the supporting columns being of five-inch extra lieaAW steel 
j)ipe. 
















6G 


LEAD BLAST EUKNACES. 


COLORADO 

IRON WORKS CO 


Silver-Lead Blast Furnace. 

This furnace was the first one snp])lie(l to a enstoiner in a remote 
locality and was operated for a long time before the construction of 
a wagon road permitted the trans])ortation of a larger furnace of 
regular construction. Subsetpiently both furnaces have been kept 
in operation. 



FIG. 40. 36" X 60" SECTIONALIZED LEAD FURNACE. 

Aside from the more numerous water connections due to the 
greater subdivision of the jackets, there is no disadvantage in a fur¬ 
nace of this kind when erected. The first cost is, however, somewhat 
higher than one of regular construction. 

Special care is taken in both design and manufacture of our sec- 
tionalized furnaces to simplify and reduce as far as possible the 
amount of work to be done at destination, as we realize the difficulties 
under which snch work is often performed. 

The corner columns are in halves to bring the parts within the 
required weight and the mantel frame is of I-beams although we 
are now supplying our patent arch-bar mantels. 




COLORADO 

IRON WORKS CO 


LEAD BLAST FURISTACES. 


67 


Silver-Lead Blast Furnace. 

1 he illustration on this page is reproduced from a photograph 
of one of three lead blast furnaces built for an important smelter. 
It represents the best type of construction throughout and is built for 
hard service. 



FIG. 41. 42" X 160" SILVER-LEAD BLAST FURNACE. 

The jackets are of flange steel, the tuyeres have the blast inlet 
at 45 degrees with blow pipes of standard pipe and individual gate 
valves placed under the bustle pipe. The caisson is of the best con¬ 
struction, with cast iron ends and steel sides reinforced with I-beams. 

The brick shaft is shown, resting upon our patent arch-bar man¬ 
tels and the manner in which the lire brick lining is carried by the 
inwardly projecting angle irons can readily be seen. The manner 
of binding the brick shaft between the mantel frame and the feed 
floor is also indicated. 

















08 


LEAD BLAST FURNACIiS. 


COLORADO 

IRON WORKS CO 


Silver-Lead Blast Furnace. 

This furnace is built with flange steel jackets and is of first class 
construction. Steel jackets not only are longer lived than cast iion, 
but are made in larger sections, thereby reducing the nnniher of 
water connections, lloth end jackets are alike and interchangeable, 
the one used on the front end has the tuyere opening plugged, while 
the one on the back end has the opening for the tap jacket bricked 



FIG. 42. 36" X 108" SILVER-LEAD BLAST FURNACE. 

11 ]), tliis offering the advantage of a point of access to the furnace in 
an emergencv. 

This furnace has onr patent arch-bar mantel construction. The 
caisson is formed of very heavy ribbed cast iron plates and rests 
upon a plate steel bottom which prevents the seepage of metal into 
the foundation. Each tiivere has its individual gate valve, located 
just below the bustle pipe and tlie blow pipes are made of standard 
steel pipe. 








COLORADO 

IRON WORKS CO 


LEAD BLAST FURNACES. 


69 


Silver-Lead Blast Furnace. 

Ibis furnace was tiesigaied for severe duty under adverse con¬ 
ditions as to zinc and snlpliur contents of the charge to be smelted, 
and two similar furnaces have been sup])lied l)y us to the same com¬ 
pany at intervals since the tirst was placed in operation. 



FIG. 43. 42" X 160" SILVER-LEAD BLAST FURNACE. 

The jackets are of flange steel plate of extra height with the 
same interior contour as would be obtained by two tiers of cast iron 
jackets. The caisson is very heavy and the brick shaft stayed and 
stiffened in a most thorough manner. AVith this furnace a portable 
steel hood was used, giving access to the entire shaft for barring 
down accretions. 










TO 


LEAD BLAST EURNACES. 


COLORADO 

IKON WORKS CO 


Silver-Lead Blast Furnace. 


The furnace here illustrated is one of three built for a large 
plant to replace ecpiipuieiit long in continued use. Ihe measnies 
adopted to resist the internal pressure of the crucible in a furnace 
of such extreme size are well shown in the engraving. 

These furnaces embodied the best ideas throughout and may be 
expected to give many years’ service in continuous operation. Each 
tuyere is connected with the bnstle pipe by standard steel pipe, and 



FIG. 44. 44" X ISO" SILVER-LEAD BLAST FURNACE. 

each blow pipe is provided with a quick opening gate valve per¬ 
manently attached to the bustle pipe, giving individual control of 
the blast. 

The jackets are of flange steel plate, of the best possible design 
and construction, and are held in position against the outward thrust 
of the charge at their tops by jack screws carried by a very heavy 
I-beam binder frame. This construction facilitates the removal of 
jackets, which has been further simplifled by an unusual width of 
the upper part of the furnace. Our automatic gas escape valve can 
be very plainly seen in the illustration. 












COLORADO 

IRON WORKS CO 


LEAD BLAST FURNACES. 


71 


Silver-Lead Blast Furnace. 


A very recently designed lead blast furnace is shown on this 
page. It is of the heaviest and most snhstantial constrnctioig and 
was hnilt for a mining })ro})erty where a smaller furnace had been 
successfully operated and where it was desired to replace the blast 
furnace with one of the most perfect construction. 



FIG. 45. 36" X 120" SILVER-LEAD BLAST FURNACE. 

The desiiiii follows onr standard lines for first-class lead fur- 
naces, and is one that we do not hesitate to recommend. The caisson 
is of cast iron, very heavy, and built in accord with onr regular 
practise whereliy expansion of the crucible can be taken care of. 
The jackets are of flange steel plate and the tuyeres of our standard 
lead furnace type with canvas lilow pi])es which have proved very 
satisfactory. A portion of the brick shaft is shown in the illustration 
to exhibit the construction betv'cen the tops of the jackets and the 
feed floor. 












r.ivAST ktuxacks. 


COLORADO 

IRON WORKS CO 


9 


Silver-Lead Blast Furnace. 


This furnace 
nace tuvei’os and 

t- 


has tiaiii>e steel jackets with our reiiular lead 
canvas blow ])i])es, and is e(]ui])])e(l wdtli 


fur- 


the 



FIG. 46. 42 " X 108" SILAG^R-LEAD BLAST FURNACE. 

Nesmith patent jacket Avater va])orizer. The illustration Avell shoAvs 
the brick shaft, arch-bar mantels, and the manner in Avhich the 
vaporizer is snp})orted by beams built into the end Avails of the shaft. 

The vaporization system not only saves Avater and dis])enses Avith 
the attention necessarily giATii to the jacket Avater Avhen the oA^er- 
floAV system is used, but is the best method of cooling- under all 
conditions. 



























COLORADO 

IRON WORKS CO 


T.KAI) I5LAST FrifXACKS. 


*70 
i f> 


Silver-Lead Blast Furnace. 

1 ho ])liot()i>ra])li hero ro])r()(liioo(l is of a round furuaoe soc- 
tioiializod for traiis])ortatioii ou uiiile hack. This furnace has flange 
steel jackets in ten sections, which, when assembled, o-ive a correct 
interior contour. Owino- to the dithcultv of keeping- small furnaces 
in o])eiation, ])roper interior lines are of jnst as much im]')ortance as 
in lar2:e furnaces. 



FIG. 47 . 3*)" SECTIONAFIZED DECAGONAL LEAD FURNACE. 

Tlie caisson is round, and formed of steel plates, and rests upon 
a bottom ])]ate to jirevent the working of metal down into the founda¬ 
tion. The columns are made in halves to bring them within the 
weight restrictions, and sn])port the circular cast iron mantle frame 
u])on which the brick shaft is erected. 

The tap jacket and s])ont are shown at the left, and at the right 
tlie lead well, a lead cooler standing beside the furnace. 





























74 


COPPER BLAST FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Matting Furnaces. 

On this piige is shown a 42 x 120 inch copper matting furnace of 
our standard type, with two tiers of steel water jackets. An auxiliary 
tap jacket and spout are provided in one side of the furnace for 
emergency use. 




FIG. 48. COPPER MATTING FURNACE WITH TWO TIERS OF JACKETS. 

The space between the tops of the jackets and the feed floor, 
instead of being filled with fire brick, is closed by a cast iron beveled 
frame extending entirely around the furnace on the inside of the 
steel mantel frame, thereby eliminating all brick-work below the 
feed floor, except that in the hearth. 















































































































































































































































































































COLORADO 

IRON WORKS CO 


COPPER BLAST EUENACES. 


75 


Copper Matting Furnace. 

Below we show a 42 x 120 inch copper matting furnace of 
late design along standard lines, in which the jackets extend con¬ 
tinuously from hearth to feed floor. 



FIG. 49. COPPER MATTING FURNACE WITH A SINGLE TIER OF JACKETS. 


This type offers advantages in that there is but one point at 
which sediment can collect, and that is below the slag and matte 
level, and in a simplification of the jacket water connections. In 
other respects this furnace is similar to the one having the jackets 
in two tiers. 








































































































































































































































































































TO 


COPPER BLAST FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Matting Furnace. 

The furnace here shown is a 42 x 240 inch copper matting blast 
furnace with jackets made without the knee bosh, and without out¬ 
side support, depending upon their own strength and stiffness to 
resist the outward pressure of the charge between the bottom plate 
and feed floor. 

In this construction the jackets are heavy and are strongly rein¬ 
forced by vertical tees of large section making them extremely stiff. 
Furnaces of this type are largely used in Arizona, and while the 



FIG. 50. COPPER MATTING FURNACE WITH SELF-SUPPORTING JACKETS 


jackets distort more than smaller ones braced as in our standard 
designs, they are nevertheless considered satisfactory by those using 
them and offer certain advantages in ease of replacement, as well as 
in a reduced number of water connections. 

A practise which also finds favor in the southwest is the work¬ 
ing of the furnace into the building structure in such manner as 
to become practically a part of it. This enables the blast and water 
piping and the overflow gutters to be carried independently of the 
furnace structure, providing a large amount of space between and 
around these parts. The manner in which these features are carried 
out is also indicated in the above illustration. 





































































































































COLORADO 

IRON WORKS CO 


COPPER BT>AST FURNACES. 


77 


Copper Blast Furnace. 

The furnace shown below is 42 x 120 inches, and is designed 
along standard lines but with a crucible for smelting oxidized or 
carbonate ores to black copper or sulphide ores to a high grade matte 
where it is preferable to make inside separation. 



We have built furnaces for such ores with jackets about 72 
inches high and with brick shaft from the tops of the jackets to the 
feed floor as in a lead furnace; we do not, however, recommend this 
construction for regular copper matting. 














































































































































































































































































































78 


COPPER BLAST FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Matting Furnace. 

Below is shown a copper matting furnace in which the blast 
enters through an air jacketed hood, whereby its temperature is 
raised to some degree. It has been found in actual practice that by 
so warming the air blast the furnace to an extent will operate anto- 




FIG. 52. COPPER MATTING FURNACE WITH AIR JACKETED HOOD. 

matically, that is to say, should too much heat rise to the top of 
the charge, the air is heated to a higher temperature and consequently 
tends to bring the combustion down to the tuyeres where it belongs. 
Moreover, in using such a large hood, the velocity of the gases is 
reduced therein and a great percentage of the fine material drops 
down into the charge. 






























































































COPPER BLAST FURNACES. 


79 


COLORADO 

IRON WORKS CO 


Copper Matting Furnace. 

The outline cut below is of a 36 x 48 inch copper matting fur¬ 
nace, recommended as greatly superior to a circular furnace for small 
capacities. 



There is a single water jacket on each side and end, 96 inches 
in height, 84 inches in height above the tuyeres, and the design is 
on the same lines as the larger rectangular furnaces. In such a 
small unit, the water jackets, if carried down to the base plate, 
increase the tendency of the matte and slag to chill in the hearth. 
For this reason the hearth is constructed of refractory brick in the 
manner shown. 














































































































































































































































80 


COPPER lU.AST FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Blast Furnace. 


’J’liis blast furnace is so desiiiiied as to facilitate cleaning’ out 
and thereby reduce the time lost from freeze-ups, Avliicli are more 
liable to occur in operating small furnaces than large ones. The 
jackets are su]A])orted from the mantel frame by chains, so that they 
can he SAvnng out Avithout the rigging necessary to take them out 
b()di]A\ In the furnace shoAvn the jackets are in narroAV sections 

t ^ * 



FIG. 54. SMAEL RECTANGIJEAR COPPER FURNACE. 


adapted to mule-back trans])ortation, but ordinarily the side and 
end jackets Avould be made in one piece. 

The remoyable crucible aauII appeal to those avIio haA^e had experi¬ 
ence in operating small furnaces. It is held in position against the 
loAver edge of the jackets by jack screAvs, and for remoyal is loAyered 
upon a truck. Two crucibles are supplied, AAdiich enables one to be 
kept in reseiu’e, and by this means the time of cleaning out is reduced 
to a fraction of that customarily required. These features, and the 
further superiority of the rectangular form, should in most cases 
outAA^eigh any considerations of less first cost of a round furnace. 

































































































































































COLOR ADO 

IRON WORKS CO 


CorPER ^SFATTING EEUXACKS. 


81 


Copper Matting Furnace. 

The furnace here shown is designed along standard lines and has 
two tiers of steel jackets, the lower side jackets being in three sections 
and the upper side jackets in one piece. The ippier end jackets are 



FIG. 55. 42" X 120" COPPER MATTING FURNACE. 


extended sidewise and carried directly by brackets cast on the corner 
colninns, these jackets in turn carrying the upper side jackets. The 
blow pi])es are of standard pipe and the valves are built into the 


tuveres. 


















82 


COPPER MATTING FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Matting Furnace. 

This illustration is reproduced from a photograph of a recently 
built furnace with 45 degree inlet angle tuyeres, blow pipes of stand¬ 
ard pipe and the Gross patent trap spout. 



FIG. 56. 42" X 120" COPPER MATTING FURNACE. 


It has two tiers of steel plate water jackets, the upper supported 
independently of any other part of the furnace by steel I-beam frame 
resting on brackets cast integral with the corner columns. The cast 
iron beveled feed plates show above the tops of the upper jackets. 
These do away with brick-work below the feed floor level. 







COLORADO 

IRON WORKS CO 


COPPER ]\rATTIXG FURXACES. 


83 


Copper Matting Furnace. 


llie eiigTaving on this ])age 
nace with two tiers of ])late steel 
being as shown on page 74. 


shows a cojp^er matting blast fnr- 
water jackets, the interior contour 



FIG. 57. 44" X 200" COPPER MATTING FURNACE. 


This furnace embodies many desirable features and is a good 
example of a modern copper matting furnace of the highest type. 
As in onr other furnaces, the upper tier of jackets is carried inde¬ 
pendently of the lower and cast iron beveled feed plates fill the space 
between the tojis of the np]ier jackets and the feed floor, eliminating 
brick-work at that point. i j., 









84 


corPEK :\rATTi]srG furnaces. 


COLORADO 

IRON WORKS CO 


Copper Matting Furnace. 



FIG. 58. 38" X 144" COPPER MATTING FURNACE. 


This furnace differs from our standard construction in some 
respects, among Mdiicli it may be mentioned that the bottom plate is 
carried on a truck. The water jacketed girder and arch-bar mantel 
system is here shown, the lower jackets being carried by hangers from 
the water jacketed girders when the bottom plate is removed. 


I 














COLORADO 

IRON WORKS CO 


COPPER :\rATTTNG EURNACES. 


85 


Copper Matting Furnace. 

This blast furnace is water jacketed from the bottom plate 
practically to the feed floor^ the jackets being in two tiers, the lower 
side jackets in sections 26 inches wide and the npper side jackets in 



FIG. 59. 38" X 180" COPPER MATTING FURNACE. 


two sections on each side of the furnace. The tuyeres have onr built- 
in valves, giV'ing easy control of the blast at each indi\idual tn\eie. 
On tills furnace is shown a copjier water jacketed spent in the center 
of the side, where it is sometimes placed in furnaces of considerable 

length. 













86 


('OPPKIi IVrATTlNG FURXACKS. 


COLORADO 

WON WORKS CO 


Hot Blast Copper Matting Furnace. 

This furnace is similar to the one illustrated on page 81 with 
respect to the arrangement of the jackets, but differs in the aiiange- 
nient of the bustle pipe, waste water gutter, etc. The bustle pipe is 



FIG. 60. 40" X 96" COPPER MATTING FURNACE FOR HOT BLAST. 

lined with vitrified asbestos cell lining to reduce the loss of heat from 
radiation, and extends entirely around the furnace, with opening 
and gate at one end for hot blast and at the other end for cold blast, 
so that the stove can be cut out and the furnace operated on cold 
blast in an emergency. The beveled frame of cast iron plates is 
shown just above the tops of the jackets. 
























COLORADO 

IRON WORKS CO 


COPPER MATTING FURNACES. 


87 


Hot Blast Copper Matting Furnace. 

This engraving is of a recent copper matting furnace designed 
for semi-pjritic smelting with a highly heated air blast. The interior 
contour is as shown in the sectional drawing reproduced on page 75. 



FIG. 61. 40" X 144" COPPER MATTING FURNACE FOR HOT BLAST. 


The tuyeres are of cast iron with onr individual, built-in tuyere 
valves and the blow pipes are covered with asbestos pipe covering. 
The bustle pipe is lined with the vitrified cellular asbestos which we 
have found so satisfactory for minimizing loss of heat. This furnace 
has the frame of cast iron beveled feed plates between the tops of 
the jackets and the feed fioor, although it was not in position when 
the lohotograph was taken. 








88 


C' OI ‘ 1’ E R ]\ r A '1' '1' IN G E E J {N A C’ S 


COLORADO 

IRON WORKS CO 


Hot Blast Copper Matting Furnace. 



FIG. 62 


36" X 84" HOT BLAST COPPER MATTING FURNACE 























COLORADO 

IRON WORKS CO 


COPPER MATTING FURNACES. 


89 


Hot Blast Copper Matting Furnaces. 

llie furnace sliown as Fig. 62 has a single tier of jackets extend¬ 
ing from the bottom plate to the frame of cast iron beveled feed plates 
at the feed lioor level. The bnstle t)ipe is of cast iron, lined with vitri¬ 
fied cellular asbestos and is placed close to the tuyeres to prevent 
nndne loss of heat. This furnace is equipped with the ISiesmith 
patent jacket waiter vaporizer by means of wdiich the consumption of 
jacket waater is reduced to a fraction of that ordinarily required. 
Since this furnace wais built the jinrchaser duplicated the order. 

In Fig. 63 w’e show^ a recently built and very efiicient hot blast 
cojiper matting furnace. The tuyere valves are located immediately 
under the bnstle pipe wfith the upper ends of the blow^ pipes connected 
to the valves through stnfiing boxes, thereby permitting the removal 
of any tuyere and blow^ wdiile the furnace is in operation, by 

first closing its valve. The bnstle pipe is lined wath vitrified cellular 
asbestos and the blow pipes are covered wfith asbestos pi]ie covering. 

The low^er waiter jackets are biaiced bv vertical steel I-beams at 
the joints to avoid the nei'essity of removing the entire binder as in the 
usual construction. The n])]ier tier of jackets is supported by a 
steel I-beam girder frame carried upon brackets bolted to the four 
corner columns. 

Hinged drop doors are fitted to the furnace bottom plate, the 
latter being rigidly snp])orted by twelve short cast iron columns. 

The furnace is arranged for automatic charging from cars run¬ 
ning along each side on the feed floor, the doors on the sides being 
hinged. The balanced door at each end of the superstructure is for 
the purpose of giving access to the interior of the furnace. 

The brick superstructure is as shown in Fig. 79 and is of ap¬ 
proved design. Its large volume of free s])ace directly above the 
furnace enahles much of the coarser fine dust to fall back u[)on the 


top of the charge instead of being carried over into the dust cliam- 
ber. Connection wdth the dowuitake leading tO' the dust chamber is 
through the circular ojiening slioivn at the top. 


90 


COPPER MATTING FURNACES 


COLORADO 

IKON WORKS CO 


Hot Blast Copper Matting Furnace. 



FIG. 63. 


38" X 180" HOT BLAST COPPER MA 


TTING FURNACE, 




















COLORADO 

IRON WORKS CO 


COPPER MATTING FURNACES. 


91 


Hot Blast Copper Matting Furnace. 

This illustration is from a photograph of a large hot blast copper 
matting furnace provided with the Xesmith patent jacket water 
vaporizer and having the lower jackets of steel plate and the upper 
jackets cast iron, a comhiuation which Ave have made to some extent. 



Our usual practice of lining the blast main leading from the 
stoA^e and the bustle pipe Avith vitrified cellular asbestos Avas folloAA^ed, 
and the interior contour of the furnace Avas correct, but some depart¬ 
ures from our approved designs Avere made at the solicitation of the 
metallurgist aaTio AA^as to operate the furnace, the most important of 
A\diich Avas the omission of the bottom plate, the space beloAv the 
jackets being bricked up solid, Avhich aa^o did not and do not lecom- 

mend. 














COPPER ^rA'l'TING FURNACES. 


COLORADO 
iron works CO 


Hot Blast Copper Matting Furnace. 




FIG. 65. 36"x60" COPPER MATTING FURNACE. 

Ill the above furnace the blast passes through an air jacketed 
hood similar to that shown on page 78 and is warmed by the heat in 
the escaping gases. Xaturally, this is a less efficient method of heat¬ 
ing the blast than our U-pipe stove, but there is nevertheless a dis¬ 
tinct gain although the air is not sufficiently heated to bring the 
operation within the designation of hot blast smelting. 


















COLOR ADO 

IRON WORKS CO 


COPPETi 


BEAST EPRNACES. 


1 ) 


o 

•) 


Copper Blast Furnace. 



FIG. 66. 36" X 60' 


COPPFJR FURNACE FOR INSIDPI SEPARATION. 


Tliis fiirnnee is boshed on the ends as well as the sides and has 
a tuyere at each end. It was designed for smelting oxide ores to black 

cojiper and eonse<|nently has a crncible. 











04 


C()I‘1‘ER BLAST FLlfXACES. 


COLORADO 

IRON WORKS CO 


Copper Blast Furnace. 



FIG. 67. 36"xlOS" COPPER FURNACE FOR INSIDE SEPARATION. 

In the above furnace the jackets are in a single tier with interior 
contour similar to onr usual practice. It was designed for a brick 
shaft between the tops of the jackets and the feed door to meet the 
desire of the purchaser. 















COLORADO 

IRON WORKS CO 


COPPER BLAST FURNACES. 


95 


Copper Blast Furnace. 



FIG. 68. 36" X 120" COPPER FURNACE FOR INSIDE SEPARATION. 

The furnace shown above was designed along standard lines. 
It has a crucible for inside separation and is adapted to smelt car¬ 
bonate ores to black copper or charges low in snlphnr to a high grade 
niattej liable to chill if separated in an outside forehearth. 

A furnace of this type is indicated for a property producing 
oxidized ore and expecting to reach sulphides upon development of 
the mine to greater de]ith. 



























roppKi; ]srAT'riN(i fukxaces. 


COLORADO 

IRON WORKS CO 


tH) 


Copper Matting F'urnace. 

^riiis ty])e of fiiniapc we I’ccoiniiieiHl in ])lace of the usual round 
furnace, as the correct interior contour can l)e secured hy jachets 
continuous throughout their entire height with the advantage of 
liaving Imt one ]ioint at whicli sediment can collect. This construc¬ 
tion also ])ermits easier access to the interior or renewal of one jachet 
section slionld it hecome damaged hy any means. In designing fui- 
naces on this general ])lan, the dO-inch is made hexagonal, 42 inch 



heptagonal, and 48-inch octagonal, except in furnaces designed for 
mule-back transportation, when the division is made as small as 
necessary to keep within the permissible weight. 

While the above furnace is particularly designed for smelting 
copper sulphide ores to matte, it will give equally as good results on 
oxidized or carbonate ores, as on sulphides; in the former case, 
separation being carried on in the crucible, while in the latter, the 
matte is separated on the outside of the furnace in some form of 
settler, and the furnace may, if desired, be run with a trapped blast 
and continuous flow of slag and matte. 























































































COLORADO 

IRON WORKS CO 


COPl’ER 15LAST FUKNACES. 


97 


Copper Blast Furnace. 

ihis blast furnace is of the same general design as the one 
shown on page 96 but has a deeper crucible, adapting it to smelting 
oxidized ores to black co])per. IMolten co})per loses its heat very 
rapidly and the brick lined crucible is necessary to ])revent chilling. 
1 he slag is tapped from the upper spout and the copper from the 
lower. 




FIG. 70. POFYGONAL COPPER BLAST FURNACE. 

A furnace of this kind is very desirable for a small property 
producing oxide, carbonate and other surface copper ores, as when 
sulphides are encountered as depth is gained the crucible can be 
bricked up solid and the ores smelted to a matte. 

AYhat is said as to sizes built, in connection with the furnace 
shown on page 96 applies here also. In the above furnace the crucible 
is made of heavy cast iron plates conforming in shape to the jacketed 
portion which can be readily taken apart if necessary. 

4 































































































08 


C()I‘1‘KK ULAST FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Matting Furnace. 



FIG. 71. 42" HEPTAGONAL COPPER MATTING FURNACE. 

The above illustration is reproduced from a photograph of a 
matting furnace 42 inches internal diameter at the tuyere level, built 
as shown in the horizontal and vertical sectional drawings on page 96, 
but Avith seven jackets and seven tuyeres instead of eight as in a 
48-inch furnace. 

In addition to the advantages due to having the jackets in ver¬ 
tical sections, we are enabled in furnaces of this type to make the 
jackets in our most approved manner, Avith no rivet heads exposed to 
the fire and all seams liroiight outAvard Avhere they are ex]iosed to 
vieAv. 

Furnaces of this ty])e are emphatically recommended Avhere the 
best obtainable is desired. 















COLOR ADO 

IRON WORKS CO 


COPPER BLAST FURNACES. 


99 


Copper Blast Furnace. 



FIG. 72. 42" HEPTAGONAL COPPER BLAST FURNACE. 

This furnace was built for smelting oxidized copper ores to 
black copper and conforms to the drawings reproduced on page 97. 
It has seven jackets with one tuyere to each jacket and is provided 
with the deep crucible within a heptagonal curb of heavy, ribbed 
cast iron plates. 

A furnace of this kind can always be easily changed to adapt it 
for copj^er matting with outside separation by bricking up the cru¬ 
cible. xVlthough the jackets do not extend as far downward as in 
our rectangular matting furnaces, it is not desirable that they should 
do so, as in copper matte smelting in small furnaces it is necessary 
to protect the hearth from chilling while in large furnaces tliere is 
usually an excess of heat at this point whicli it is well to dispose of. 













100 


COri’Eli 15 LA ST FURNACES. 


COLORADO 

IRON WORKS CO 


Copper Blast Furnace. 

This furnace is constructed with steel i)late water jackets along 
the lines of the drawing shown on page 00, but being designed for 
transportation on mule-back, Avith a further subdiAusion of the jackets. 

The horizontal section at the tuyere leA^el is that of a decagon, 
AATtli a tuyere in eA'ery other jacket, that is, AAuth ten jackets and fiA^e 



FIG. 73. 3G" SECTIONALIZED DECAGONAL COPPER FURNACE. 

tuyeres. There is an upper tier of fiA^e jackets. Xo single piece of 
this furnace AA’eighs oatf 325 pounds. 

AVe also build d2-inch and dS-inch furnaces sectionalized in the 
same manner, AAdiich in metallurgical results are equal to those not 
sectionalized, and our large experience in this line enables us to meet 
problems of this kind in a most satisfactory manner. 











COLORADO 

IRON WORKS CO 


COPPER BLAST FURNACES. 


101 


Copper Blast Furnace. 

The engraving and sectional view on this page show our circular 
copper furnace with plate steel water jacket constructed in vertical 
halves and with continuous hosh from bottom to top. The crucible 
in this case is built entirely independent of the jacket and where 



FIG. 74. 36" ROUND COPPER BLAST FURNACE. 


oxidized or carbonate ore is to be smelted, the crucible is made in 
two pieces securely bolted together. The circular "w ind box being 
also in halves, the whole may be very easily taken apart for cleaning 
out. Each tuyere is entirely independent of all others and has an 
air-tight gate in order to control the air blast. 


























































102 


COPl’EH 1U.AST FUPNACES. 


COLORADO 

IRON WORKS CO 


Copper Blast Furnace. 


This furnace was 42 inches in diameter at tlie tuyeres. Tlie 
jacket is in three ring-like sections, and while this makes the secur¬ 
ing of a pro])er interior contour a simple matter, the three points 
at which sediment can collect is a great disadvantage and Ave Avould 
not recommend such a furnace where the water was not of the best. 



FIG. 75. 42" ROUND COPPER BLAST FURNACE. 

The 2^esmith patent jacket Avater vaporizer is shoAvn in place 
on this furnace, and this minimizes the amount of sediment deposited, 
both by reducing the amount of Avater used and by the settling of 
solids in the drum. The vaporizer drum has an air jacket built upon 
it for the purpose of Avarming the blast, but the amount of heat which 
can be put into the air by this means has piwed small and the com¬ 
plication of the blast piping is considerable. 







COLORADO 

IRON WORKS CO 


COPPER BLAST FURXACES. 


103 


Copper Blast Furnace. 


1 li6 chief rocoiiiiiieiidatioii of the round furnaces shown in Fi£>’s. 
i () and < i is lower first cost than the others illustrated, hut as there 
are places where they will serve, and as we are called upon to furnish 
them occasionally, we continue to show them. 



The jacket in both of these furnaces is in one jiiece with one 
vertical seam on the fire side, the outer sheet being’ extended down¬ 
ward to form the curb of the crucible. The furnace shown as Fig. 76 
has our tuyeres with individual built-in valves, a spout wdth jacketed 
tip, and is more substantial in these respects than the furnace desig¬ 
nated as Fig. 77, which, while retaining the best of material and 
workmanship throughout, is intended to be the cheapest that can be 
furnished for real work. 































































104 


COPPEK BLAST FUPXACES. 

Copper Blast Furnace. 


COLORADO 

IRON WORKS CO 


N' . 

/ 



FIG. 77. 36" ROUND COPPER BLAST FURNACE 












COLOR ADO 

IRON WORKS CO 


dust CIIAAFBKKS. 


105 


Dust Chambers. 

The dust cdiauiher here illustrated is an efficient and popular 
onOj especially in connection with copper matting furnaces. In 
copper matting practically all of the values carried out of the furnace 
by the escaping gases are in the form of solid dust particles which 
settle with comparative readiness when subjected to relatively undis¬ 
turbed conditions. This is accomplished by passing the gases through 
a hue or chamber of such large cross sectional area that their velocity 
is low and sufficient time is therefore allowed in which the particles 



FIG. 78. BALLOON SHAPED DUST CHAMBER. 

can settle through the distance necessary to reach the bottom where 
they remain until withdrawn. 

The hue is balloon shaped in cross section, made in any diameter 
from four to ten feet, and of suitable length. Draw-oh gates are 
placed at intervals along the bottom, f?‘om which the accumulated hue 
dust is conveniently drawn into wheelbarrows, although with hues 
of very large diameter, collecting a great amount of dust, we can 
furnish them with a screw^ convevor in the bottom wdiich conveys the 

«. t/ 

dust to one end of the hue and deposits it, thus eliminating a large 
amount of manual labor. 

The preferred location for the dust hue is on the feed hoor level, 
where it is suspended, leaving ample head room beneath it. 














lOG 


BLAST FUBNACE HOODS. 


COLORADO 

IRON WORKS CO 


Blast Furnace Superstructures. 



FIG. 79. BRICK SUPERSTRUCTURE FOR COPPER MATTING FURNACES. 


/ 































































































































































COLORADO 

IRON WORKS CO 


15LAST FrjfXACK HOODS. 


107 


Blast Furnace Hoods. 

In Fig. 79 is sliOAvn a A^ery desirable form of brick and slieet 
steel snperstrnctnrej particularly so for copper matting’ furnaces run¬ 
ning Avitli a hot top, and AAdiere a dust chamber is used. 

d be structural materials used immediately aboA’e the furnace 
shaft being brick and cast iron are those best suited to Avithstand 


the high temperature to Avhich they are subjected, and the sheet steel 
due may be lined AAuth brick for AAdiatcA^er distance is necessary. Tn 



FIG. 81. AlOAXABLE STEEL HOOD FOR LEAD BLAST FURNACES. 

copper matting furnaces AAdiich are driA’en hard a large proportion of 
the due dust is relatiA^ely coarse and settles rapidly. The hopper 
bottom to the drst section of the downtake proAudes simple means 
for collecting this coarse material. A hood of this kind is sIioaaui on 
the furnace illustrated in Fig. 03. 

The moATil)le steel hoods sIioaaui in Figs. 80 and 81 are particu¬ 
larly adapted to lead furnaces. They haA^e a Avheel at each corner on 
an eccentric axle. AVhen the hood is to be moA^ed aside to giA^e access 
to the furnace shaft for barring doAAm, the telescoping sleeAm forming 
connection AAuth the dxed portion of the stack is disconnected, the hood 
raised on the AAdieels by operating the eccentric axles and rolled aside, 
leaAung the entire top of the furnace shaft exposed, the fumes passing 
largely off by the stack. Although the drst cost of this hood is greater 
than that of the iron AA^ork as usually furnished for a brick super- 











108 


BLAST FUKNACE HOODS. 


COLORADO 

IRON WORKS CO 


structure, wlieu the cost of erec¬ 
tion is cousiclered there is prac¬ 
tically no difference in the final 

tj 

cost. 

The illustrations on this page 
are from photographs of hoods for 
small furnaces. Fig. 82 is of a 
hood for a round copper furnace 
and presents the general features 
of the type most commonly used. 

This hood is circular in plan and 
is made entirely of sheet steel. 

•There are two charging doors 
placed opposite each other and 
proyided with counter balancing weights so arranged as to make the 
entire hood self-contained. These charging doors do not conform to 
the curyature of the hood but are hat, thus reducing the tendency 
to warp and bind. Tins type of hood is also generally supplied with 
our polygonal copper furnaces although we sometimes furnish a 
hood with doors hinged at their upper ends as shown in Fig. 54. 

The hood shown in Fig. 83 is for a small rectangular lead 
furnace and is of a design which leayes little to improye upon. 

The lower part is pyramidial in 
shape and conforms to the lines 
of the shaft. This enables the 
charging doors to be placed on 
the sloping sides where their 
weight retains them in contact 
with the ways in which they 
slide, and permits open slide 
ways to be used, thus eliminat- 

ty 7 

ing binding due to warping. 

The telescoping hood shown 
on the furnace illustrated in 
Fig. 30 has the adyantages that 
the charges can be shoyeled into 
tbe furnace from any point and 
that raising the hood giyes ac¬ 
cess to the entire interior. 



FIG. 83. FURNACE HOOD. 





FIG. 82. FURNACE HOOD. 










COLORADO 

IRON WORKS CO 


ULOWKRS. 


109 


Positive Blowers. 

% 

llic niaiintactiire of blowers is a s])ecialty. The Connersville 
I)l(nver Co., whose blowers we have sold for many years, has devel¬ 
oped a machine which for efficiency, reliability and durability meets 
the most exacting demands. We believe satisfaction with them has 
been universal, and we continue to recommend them without quali¬ 
fication. 



FIG. 84. CONNERSVILLE POSITIVE BLOWER. 

This type of blower is the best for lead and copper smelting, 
showing higher efficiency at the pressures used in that work than 
either fans or blowing engines, and without the uncertainty in volume 
delivered by the former. The power is practically proportional to 
the displacement and pressure and tests have shown that, when oper¬ 
ating against a pressure of o2 to 56 ounces, from Sd to 86 per cent, 
of the indicated horsepower of the engine is transformed into energy 
in the blast. The power required may be taken at five horsepower 
for each 1,000 cubic feet free air per minute at one pound pressure. 

The regular sizes are as follows: 

SIZES, SPEEDS, WEIGHTS, ETC., OF CONNERSVILLE BLOWERS. 


Displacement 
Cubic Feet 

Speed 

R.P. M. 

Size Pulley 
Inches 

Horsepower 
at 32 Oz. 

Outlet 
i Diameter 

Weight 

Pounds 

13 

250 

42 

X 

7 

32 

14-in, 

6,000 

17 

225 

42 

X 

8 

38 

16-in. 

7,400 

24 

200 

48 

X 

10 

48 

18-in. 

9,000 

33 

190 

60 

X 

12 

62 

20-in. 

13,300 

45 

180 

66 

X 

14 

81 

20-in. 

16,000 

57 

170 

72 

X 

16 

97 

24-in. 

20,000 

65 

160 

84 

X 

16 

104 

24-in. 

23,700 

84 

150 

84 

X 

20 

126 

27-in. 

26,000 

100 

140 

96 

X 

20 

140 

30-in. 

36,000 

118 

130 

120 

X 

20 

153 

30-in. 

42.000 































no 


BLAST (LVTKS. 


COLOR ADO 
IRON WORKS CO 


Blast Gates. 


FIG. 85. BLAST GATE. 

Our blast, gates are constructed in the same manner as a Avater 
gate, Avith the pressure on one side. They are well designed and 
thoroughly fitted, the A^ah^e stem Avorks through a stuffing box and 
the entire A^ah^e is air tiffht. 

o 

We haA'e patterns for the style shoAvn in Fig. 85 in all regular 
sizes from tAA^A^e to thirty inches in diameter. 




FIG. 86. RACK AND PINION BLAST GATE. 

The loAver illustration on this page shoAvs the gate AAuth a rack 
and pinion operating mechanism. We are prepared to furnisli all 
sizes to Avork by a hand AAdieel in this manner, but the attachment 
is only desirable in gates tAA^enty-foiir inches in diameter and oA’er. 




COLORADO 

IRON WORKS CO 


BLAST GATES. 


Ill 


J lie engraving on this page shows an improved type of rack 
<111(1 pinion actuated gate. It is well ribbed to prevent siiringing of 
the parts with consecpient leakage of air. The body parts are planed 
where they fit together and the pinion shaft is fitted Avith a stnfiing 
boxy making the entire gate air tight. The rack is cast integral Avith 
the ATdve, is planed on the sides, and slides in a grooA’e planed in the 
liody, thus forming a guide. The gate also hears tAA’o broad ribs at the 



FIG. 87. RACK AND PINION BLAST GATE. 


sides of the rack Avhich are also planed and slide betAveen two corre¬ 
sponding finished surfaces on the inside of each half of the body. 

A blast gate made in this Avay is A^ery compact and durable, but 
is necessarily more expensive to build than onr other type of rack 
and pinion gate. Where blast gates are opened and closed frequently 
and rapidly, this is the best type of gate on the market, as it is easily 
operated even nnder lieaA^y blast pressure. 

We can furnish this gate in the princi])al sizes, 15, IS, 20, 24 
and 30 inches diameter. 






HOT BLAST STOVES. 


COLOR ADO 

IRON WORKS CO 


FIG. 88. U-PIPE HOT BLAST STOVE. 





























COLORADO 

IKON WORKS CO 


HOT BLAST ST0VP:S. 


11 


Hot Blast Stoves. 

There are no combustible gases escaping as waste from the copper 
or lead blast furnaces which could be utilized as fuel for preheating 
the blast. Therefore, the Siemens regenerative or brick cbeckerwork 
stove can not be used, and the beating must be performed in some 
other a]iparatns, suitable for burning other fuel. 

The U-pipe stove, substantially as described and illustrated here, 
was the best in design and construction ever used for beating the blast 
in iron smelting before the introduction of the Siemens regenerative 
stove, and a knoAvledge of the facts caused us to adopt this desigm in 
the first stoves we built for use in copper smelting. 

This principle bad been so well worked out by iron smelters 
that we have retained it, and we have added only such improvements 
as several years’ ex])erience has shown to be of undoubted worth. 
These improvements relate not only to efficiency, but to durability 
and convenience in operation and repair. 

The plan is one which lends itself to easy attainment of any 
desired capacity and the entire apparatus is of such simple design 
and substantial construction that it forms a uio^t reliable item in 
the equipment of a smelting plant. 

Attempts upon the part of others to make U-pipe stoves have 
resulted in failure to such a degree as to cause a lack of confidence 
in them upon the part of some metallurgists. These attempts have 
involved departures from two very necessary details of construction, 
which were made in the interest of cheapness without a realization 
of the consequences which must necessarily follow. 

The two necessary features to which we refer are: The pipes 
must not be exposed to the intense flame in the vicinity of the fire 
box, and proper provision for ex])ansion and contraction must be 
made, the former to prevent local burning through of the pipes and 
the latter to avoid their breakage or leakage in the joints. Other 
attempts we have seen, embodying joints within the stoves, the sub¬ 
stitution of welded steel pipe for cast iron, etc., were such wide 
departures from the evident requirements that they need not be 
discussed. 

Properly designed and built, and operated with ordinary care, 
the U-pipe stove is not more subject to stoppage or accident than is 
the blast furnace or the roasting furnace or other apparatus forming 
parts of the complete smelting ]>lant. 

Air, in common with other gases, is a very poor conductor of 
heat, and when a mass of it is to be raised in temperature the heat 
is communicated to the juart remote from the heated contact surface 
mainly by currents causing circulation within the mass. 


114 


HOT BLAST STOVES 


COLORADO 

IRON WORKS CO 


4'o provide greater eoiitaet surface than tlie ])laiH ])i])es formerly 
used, we devised and ])ateiited onr special U-])i]>e with internally 
j)rojectiiig ribs. This is showm in cross section in Fig U2. These 
])i])es have donhle the internal surface of ])lain ])i])es of like diameter, 
making onr stove so mnch more etlicient that hnt half the length 
of i)i]>e is recpiired. Here the purchaser gains by the saving of a 



FIG. 89. PLAN OF T^-PIPF HOT BLAST STOVE. 



large amount in first cost and expense of installation. A further 
improvement, more recently added, is an enlargement of the pipe at 
the bends to increase the area and reduce friction. Our present 
IJ-pipe is therefore as illustrated in Fig. 91. 

The complete stove consists of a number of pipes usually made 
up in sections of four series, each series comprising 0, 7 or 8 pipes, 
thus making a total of 24, 28 or 32 pipes. The number of pipes 
in each series depends on the desired time of contact and the number 


















































































































































































































































































































































































































COLORADO ^ ^ ^ 

IRON WORKS CO HOT BLAST STOVES. 11 0 



of series and sections is determined by 
the velocity of the air passing through 
the pi})es. 

The i)ipes are planed where they 
ai’e connected together, and are coupled 
lip with asbestos gasgets, making air¬ 
tight joints. ddiey are tiexibly snp- 
liorted from I-beams carried liy the 
brick walls and are free to adjust them¬ 
selves to take np expansion and contrac¬ 
tion. 

The blast enters the series of pipes 
thronali a rectangnlar cast iron mani- 
fold at the rear end of the stove and 
leaves it bv a similar bnt larger mani- 
fold at the front or fire-box end. The 
manifolds are nsnally bricked in, or 
covered with asbestos cement, to pre¬ 
vent loss of heat by radiation. 

Below the elbows on the B-pipes 
are flanges, shown in Fig. 91. When 
the pipes hang in place these are all on 
a level, and npon them are placed spe¬ 
cial fire clay tiles. Upon these tiles 
is a filling of ashes, covering the en¬ 
tire ends of the pipes which project above the tiles. This forms a cheap 
insnlatinn, and wdien a pipe is to be replaced the ashes are removed 
where necessary and the tiles which rest on the pipe to be changed are 
lifted off. All bolts being ontside the heating chamber, it is nnnecessarv 


FIG. 91. U-PIPE. 


to enter the stove at any time, and repairs, wdiich are infrequent, can 
be rapidlv made. During the making of such rejiairs it is not neces- 



sarv to shut down the blast fnr- 

tj 

mice, bnt only to run it temporar- 
ilv on cold blast. 

A proper design of the brick- 
Avork prevents the intensely hot 
gases from the fire box from im¬ 
pinging on the pipes and as onr 
U-pipes do not break from temper¬ 
ature changes, Ave feel Ave can 
safely claim to furnish a stove free 
from defects and capable of giving 
liighlA" efficient service under ac- 
tiial o])erating conditions. 













LEAD COOLERS. 


COLORADO 

IRON WORKS CO 


11C) 


Lead Coolers. 

The lead cooler shown in the engraving on this page is designed 
to receive the lead from a blast furnace instead of ladling it directly 
into moulds. AVe recommend it as it makes it possible to ship a 
cleaner bullion by skimming before moulding. 



FIG. 93. LEAD COOLER. 


The lead cooler consists of a lead kettle with fire box beneath, 
enabling the lead to be*kept in perfect liquid condition for the 
removal of dross. 

AA^e usually supply them in one of two sizes, with kettles re¬ 
spectively 20 inches in diameter by 12 inches deep and 26 inches 
diameter by 17 inches deep. They are of cast iron plates, very 
heavy, and designed to have a brick lining. They are assembled 
before shipment and are furnished with grate bars and stack. 











COLORADO 

IRON WORKS CO 


PORTABLE FOREIIEARTIIS. 


117 


Forehearths or Settlers. 

The engTaving on this page shows our standard form of portable 
forelieartli or matte settler used with the smaller and moderate sized 
furnaces. For large furnaces, especially where matte storage is 

required for a converting plant, the stationary forehearth is generally 
used. 



FIG. 94. 58" X 32" X 24" PORTABLE FOREHEARTH OR SETTLER. 

This portable forehearth has a body made of heavily ribbed cast 
iron plates bolted together, ready for the fire brick lining. The 
spout is removable and an adjustable matte tapping block with cool¬ 
ing pipe cast inside is provided. It is very heavily built and adapted 
to withstand the temperature changes and rough usage to which it is 
liable to be subjected. 

We build this forehearth in the following sizes: 

30 inches wide, 54 inches long, 30 inches deep. 

30 inches wide, 72 inches long, 30 inches deep. 

48 inches wide, 00 inches long, 30 inches deep. 

72 inches wide, 72 inches long, 30 inches deep. 








I’() irrAr.LK k()k’ e ii ka irr 11 s. 


COLORADO 

IRON WORKS CO 


1 Ks 



FIG. 95. 72" X 36" X 36" PORTABLE FOREHEARTH OR SETTLER. 


The above cut represents a form of foreheartli for copper matt¬ 
ing furnaces, with or without a turntable placed on the truck imder- 
ueath the body. These are furnished in several sizes, 

c 



FIG. 96. 90" X 42" X 36" PORTABLE FOREHEARTH OR SETTLER. 












COLORADO 

IRON WORKS CO 


I’OKTABLE rOREIIEARTIIS. 


119 


The ilhistvation, Fig. 9G, shows the manner in which our port¬ 
able forehearths of the general design shown in Fig. OT are con¬ 
structed when of considerable length. The upper parts of the sides 
are stitfened by T-rails and the lower edges are carefully fitted inside 
of a riange cast around the edge of the bottom plate. 

The matte tap is a heavy block of cast iron, with an extra heavy 
cooling pipe cast inside around the tap hole. Both this block and its 
spout are adjustable vertically, and are held in place by two gib head 
steel wndges. 



FIG. 97. 12S"x79"x54" PORTABLE FOREHBARTH OR SETTLER. 


The above engraving is from a photograph of an nniisnally large 
portable forehearth three of which wn built for a large foreign lead 
smelting plant. The body is 10 feet 8 inches long, 6 feet 7 inches 
wide and 4 feet 6 inches deep, inside measurement. In’this instance 
they are used as matte and lead settlers, and for this reason they 
were provided with two taps on one side, one for the lead and one 

for the matte. 

To secure the necessary strength notwithstanding their great 
length, the sides were made of one-half inch steel plate, stiongB 
reinforced with heavy I-beams. The w^eight of the forehearths was 
necessarily great, and they Avere consequently mounted on swivel 
trucks of regulation pattern instead of upon four wdieels as is usual 
with forehearths of smaller size. 







120 


p () irr A 1 5 T . I-: ) i? k 11 e a irr i i s . 


COLORADO 

IRON WORKS CO 



PIG. 98. 72" X 42" X 30" SPECIAL PORTABLE FOREHEARTH. 

The above engTaving shows a type of forehearth soiiietinies used 
under the slag spout of lead furnaces to recover lead and matte 
carried out mechanically in the slag. It wTll be observed that the 
bottom of this forehearth is in the form of a pan. ]\Iolten lead is 
carried in this to receive the lead which settles out, the matte collect¬ 
ing in a layer on top of the lead. 



FIG. 99. 108" X 48" X 48" PORTABLE FOREHEARTH OR SETTLER. 












COLORADO 

IRON WORKS CO 


rORTABLE FORE HEARTHS. 


121 


The forelieartli shown in Fig’. 09 is of our standard type, with 
side plates made in sections reinforced hy I-heams owing to their 
considerable lenglh. The matte tapping block is of cast iron with 
cooling pipe cast inside, held in position, together with the spout, 
by gib head steel wedges. 

This illustration shows a slag granulating gutter attached to the 
end, below the overHow spout. It consists of a cast iron trough into 
the end of which the slag flows, being met by a stream of water under 
pressure issuing from the flattened nozzle sliown in the illustration. 



Beneath this nozzle is another opening, through which the overflow 
water from the jackets is discharged. The high pressure stream 
granulates the slag and the jacket water, which is in greater volume 
but at low pressure, serves to transport it. This is by far the 
cheapest method of slag disposal, but its use is limited to places where 
the slag dump is well below the level of the furnaces. 

Some furnace men prefer round settlers. That shown in Fig. 
100 is the same in all essential particulars as our round stationary 
forehearth, except that it is mounted on wheels to permit its removal 
for relining. It is shown with a waste water gutter at the bottom, 
to collect the cooling water flowing down the curb. We build fore¬ 
hearths of this type in all sizes from eight to fifteen feet diameter. 








































































































































122 


S'r AT r() NA \i Y FOI?E 11EA ITF11S. 


COLORADO 

IRON WORKS CO 


Stationary forelieartlis of the general ty])e illustrated on this 
page are at })resent in more general nse in ])lants of considerable 
size than the rectangnlar mounted ones. Ily reason of tlieir large 
area the danger of mechanical loss ot matte is reduced to a minimum, 

O 


and a large storage ca])acity for the matte is secured, Avhich is impor¬ 
tant in connection with converter plants. 

The large volume favors sc])aration although the contents chill 
at the points remote from the travel of the highly heated material 



PIG. 101. STATIONARY FOREHEARTH OR SETTLER. 

and, as in smaller forehearths, a crust forms Avhich will support the 
Aveight of a man. 

These forehearths are made of lieaA^y steel plate, the form mak¬ 
ing it a simple matter to jirovide the necessary strength. They are 
lined Avith refractory brick, such as magnesite, and as the shell is 
cooled by a spray from a pipe encircling the curb near the top, there 
is but little trouble due to corrosion or burning out. These fore- 
hearths, Avhen receiving a continuous stream of slag and matte of 
suitable volume, are kept in service for a very long time. 

Usual sizes are eight, ten, tAAxlve and fifteen feet diameter, Avith 
matte tapping block suited to the service required. 







COLORADO 

IRON WORKS CO 


:matte settling SYSTE:\r. 


12.3 


Matte Settling and Separating. 

I lie engraving on this page illustrates an equipment for settling 
and separating matte from slag, ’vvliicli consists essentially of a series 
of settling pots with suitable pits in the groniid to accommodate 
them with their tops at the general level of the snrface, in order 
that they may be conveniently filled with tlnid slag. After standing 
a sufficient length of time to allow the slag and matte to separate, 



FIG. 102. MATTE SETTLING SYSTEM. 

the pot is raised out of the pit, the slag tapped by a tap hole in the 
side of the pot, the matte tapped at the bottom, and finally the pot 
dumped to discharge the skull or shell of matte which has chilled all 
over the inner surface. 

The equipment consists of an overhead tramway erected over 
a line of pits in connection with suitable traverse and hoisting 
machinery adajited for transferring the settling pots to any point 
along the line, lowering away into the pits when empty, hoisting 
them out wdien full and transferring them to a convenient point for 
tapping the slag into slag trucks for conveyance over the dump. After 
the slag is thus tapped from a settling pot the latter is transferred 
along the line to some convenient point wdiere the matte is tap]ied 







124 


:\rATTE SETTLING SYS^'EM. 


COLORADO 

IRON WORKS CO 


into suitable molds, from a tap hole near the bottom. Tlie settling 
pot is then dnm])ed by macbinery at any convenient point on the 
line, depositing the sheil of chilled matte on the ground. The pot is 
then hoisted away, transferred to a ])oint over any pit and lowered 
into it to be filled again with fluid slag. And so with all the settling 
pots in the system. 



FIG. 103. TRANSVERSE SECTION THROUGH MATTE SETTLING SYSTEM. 

The hoisting and traverse machinery and the overhead tramway 
with its equipment of trolleys, ropes, pulleys, sheaves, etc., are of a 
system such as we have had in successful use for some twenty-five 
years at our Avorks for hoisting and transferring heavy machinery, 
and it is well adapted for the service of handling settling pots in 
such a system as that above described. The outline cut above shows 
some of the general features of the construction. 

This matte settling and separating system was worked out and 
built by us for a large western lead smelter where it was in continual 
satisfactory operation for several years prior to the shutting down 
of the plant following its consolidation with others. 
































































COLOR ADO 

IRON WORKS CO 


SLAG TEUCKS. 


125 


Slag Trucks. 

The slag truck as made at the present time is the result of devel¬ 
opment by us in the endeavor to supply our customers with larger 
and more efficient slag disposal equipment necessitated by the con¬ 
stantly increasing capacity of their furnaces. The need of such a 
device was first felt when the slag dumps became large and the dis¬ 
tance to which slag had to be hauled increased. At first the slag truck 
was small and simple, but it has now become equal to all demands 
as to capacity and ease of operation. 



FIG. 104. LFiVER DUMPING SLAG TRUCKS OF 12 CU. FT. CAPACITY. 

The first great improvement was the rolling trunnion, originated 
by us, which causes the pot to dump well beyond the side of the track. 
To this have subsequently been added the screw dump feature, and 
finally, the Fitts patent worm release. Meanwhile Ave have studied 
our slag trucks in actual use and have ascertained Avherein certain 
details could be improA^ed. HaAdng made good use of our exceptional 
facilities in this direction, Ave have found among other things the 
proper iron mixture and the best forms of boAvls to Avithstand the 

severe duty imposed upon them. 



12(1 


SLAG TKUCKS. 


COLOR ADO 

IRON WORKS CO 


Of tlie very great number of slag trucks we have built, we have 
selected a few for illustration on the following pages, wbicli wdll 
serve to show the variations in size and design. J bey are of two 
general types, those dumped by a hand lever, and those operated 
by a screw in connection Avitli a worm wdieel on the trunnion. All 
are so balanced that they are top-heavy when full, but stable in the 
upright position and the dumping lever is thus necessary only as a 
means of controlling the side on wdiich the pot is to dump. The 
screw dump cars, while having the bowls balanced in the same man¬ 
ner, permit them to be dumped slowly, as Avhen it is desired to retain 
a shell in the boAvl for resmelting. The righting of an ordinary 
screw dump boAAd is sIoav, and to OA^ercome this the Fitts ])atent 



FIG. 105. SCREAA" DUMPING SLAG TRUCKS OF 45 CU. FT. CAPACITY. 


Avorm release Avas deAused. It is used for disconnecting the Avorm 
from the Avorm Avheel, after the pot is dumped, to alloAV it to return 
to the upright position by gravity. 

The dimensions noted in the descriptions on the folloAving pages 
apply only to the particular trucks illustrated. The desiguis are 
susceptible of changes and may embody platforms and brakes at one 
or both ends. AVe shall be glad to furnish dimensions Avithin Avhich 
Ave can build trucks conforming to specified restrictions. 

Our designs, having come into such general use, have been 
extensively copied, but our opportunities for observing the Avork of 
slag trucks at all the AA^estern smelters have enabled us to maintain 
our position in advance of all others in the manufacture of this class 
of equipment. 

AAA build slag trucks in all sizes and believe Ave can meet all 
demands upon us in the future, as Ave haA^e done in the past. 







COLORADO 

IRON WORKS CO 


SLAG TRUCKS. 


127 


Lever Dump Slag Truck. 

J lie eiigTaving shown herewith represents one of a lot of sixteen 
slag trucks of nine cubic feet capacity, shipped to Mexico. They are 
designed to receive a single ta]p)ing‘ of slag from lead blast furnaces. 



FIG. 106. 9 CU. FT. SINGLE BOWL LEVER DUMP SLAG TRUCK. 


These trucks were built to run in trains, each, however, being con¬ 
trolled bv foot brakes. 

tJ 

The bowl is hemispherical and is dumped by means of a hand 
lever at one end. The locking device shown retains the bowl in its 
upright position when tilled with molten slag and in transit. 

The entire height of truck from the top of the track rail to top 
of bowl is thirtv-six inches, and gauge of track twentv-four inches. 








12S 


SLAG TIirCKS. 


COLORADO 

IRON WORKS CO 


Lever Dump Slag Truck. 

The slag truck shown below is of a type of which we have 
built a large iiuuiber. The bowl has a ca])acity of twelve cubic feet. 
The dumping is effected by a lever, the bowl returning to the upright 
position by gravity and being then held against tipping by hooks. 

The fSTesmith patent double bowl slag truck was originally de¬ 
vised to provide greater capacity than obtainable with a single round 



FIG. 107. 12 CU. FT. SINGLE BOWL LEVER DUMP SLAG TRUCK. 


bowl, without increasing the height. Besides its use as the main 
equipment for slag disposal, it is also used at some plants having 
larger trucks, for the purpose of trimming the surface of the dump. 

The bowls have each a capacity of 7.8 cubic feet, a total of 15.6 
cubic feet for the truck. The bowls are carried by trunnions in a 
frame which swivels on a central pivot, thereby securing stability in 
haulage and the ability to exercise effective control in dumping. 
The design also permits of dumping the slag well beyond the track. 
The illustrations show the truck in position for haulage and with 
one bowl dumped. Hand brakes provide for control of speed in 
going dowui grade. 





COLORADO 

IRON WORKS CO 


SLAG TRUCKS. 


120 


Lever Dump Slag Truck. 



FIG. 108. 15.6 CU. FT. NESMITH PATENT DOUBLE BOWL SLAG TRUCK. 



FIG. 109. 15.6 CU. FT. NESMITH PATENT DOUBLE BOWL SLAG TRUCK. 

5 











SI.A(J r RUCKS. 


COLORADO 

IRON WORKS CO 


i;}() 


Lever Dump Slag Truck. 

On this })age we illustrate a lai’i>*e elliptical howl lever (lnni])ini>’ 
slag truck. It combines large ca])acity with small h('ight, features 
which will enable many who desire to increase their tramming capac¬ 
ity to do so without incurring the expense of relaying tracks or 
lowering their tracks in ihe truck stations. The bowl is top-heavy 
when full and self-righting when empty. 



FIG. 110. 31.7 CU. FT. EI.FIPTICAI. BOWE SBAG TRITCK. 


The total height from top of rail to top of bowl is three feet, 
seven and one-half inches, but little more than the Xesmith double 
bowl truck, and the overall length is fourteen feet, four inches. The 
overall length is subject to change, depending on whether a platform 
is placed at one or both ends. 

An examination of the illustration will show that there is no 
supertluous height, lly careful study we have worked out designs 
for our large slag trucks in which the running gear adds the least 
possible amount to the actual height of the bowl, thus providing the 
maximum capacity with the minimum height. 








COLORADO 

IRON WORKS CO 


SLAP. TRrrivS. 


i:n 


Lever Dump Slag Truck. 


FIG. 111. 44 CU. FT. SEMI-ETLIPTICAL BOWL SLAG TRUCK. 

The two eiiiiTavings on this page show our 44 cubic foot capacity 
seuii-elliptical bowl slag truck, which operates and is built ou pre¬ 
cisely the same principle as the 41 cubic foot elliptical bowl truck 
just described. AVe furnish these with or without platforms at one 
or both ends, and with brakes, or simply with draw heads and draw 
bars when the trucks are handled in trains. The height from top 
of track rail to top of bowl is 44 inches. Approximate shipping 
weight 8,500 pounds. 


1 




FIG. 112. 


44 CU. FT. SEMI-ELLIPTICAL BOWI> SLAG TRITCK. 









132 


SJ.AG TKLICKS. 


COLORADO 

IRON WORKS CO 


Screw Dump Slag Truck. 

Hie illustration on tliis page shows a screw dninp slag truck 
with a round bowl of 25 cubic feet capacity, and with platform and 
band brake at one end. In this construction the bowl is carried in 
a beavv steel band, the trunnions being attached to the band, this 
device facilitating renewal of the bowl. 



FIG. 113. 25 CU. FT. SCREW DUMP SLAG TRUCK. 


The truck shown has the Fitts patent ^vorm release mechanism, 
but customers can exercise their preference as to this and other 
features as we can and do furnish our slag trucks with any combina¬ 
tion of details desired. 

• In a slag truck of 25 cubic feet capacity, there is no great diffi¬ 
culty in keeping down the height. In this one a height from top of 
rail to top of bowl of three feet, three inches is secured with a round 
bowl five feet, six inches outside diameter, this being also the extreme 
width of the truck. The overall length, with platform at one end 
as shown, is eleven feet, one inch. 













COLORADO 

IRON WORKS CO 


SLAG TKUCKS. 


133 


Screw Dump Slag Truck. 



FIG. 114. 35 CU. FT. ROUND BOWL SCREW DUMP SLAG TRUCK. 

The slag truck shown on this page measures four feet, seven 
inches from to}) of rail to top of bowl, lias an extreme width of six 
feet and an overall length, with platform on each end, of thirteen 
feet, six inches. 

The construction of the screw dinii]) mechanism is well shown in 
the illnstration. The bowl is carried on wheels fixed to the trunnions, 
these wheels roll on the rails at the ends of the truck frame. Adja¬ 
cent to the rail is a rack engaging a gear carried by the trunnion, 
these parts assuring the return of the bowl to the central ]iosition. 
Placed next the gear is a worm wheel, which, with the transverse 
screw or worm, serves to control the dumping of slag. 



FIG. 115. 


35 CU. FT. ROUND BOWL SCREW^ DUMP SLAG TRUCK. 






















i:U 


ST.AG TKCCKS. 


COLORADO 

IRON WORKS CO 


Screw Dump Slag Truck. 

'J'he slag truck illustrated ou this i)‘'ig‘e is similar to the one just 
(leserihed, except that the howl is carried in a truiinioii ring instead 
of on trunnions forming paid, of the bowl casting, and that it is 
equipped with the Fitts patent worm releasing attachment, lii other 
respects the two trucks are similar, and of the same dimensions, very 
nearly. 



FIG. 116. 35 CU. FT. ROUND BOWL SCREW DUMP SLAG TRUCK. 


A comparison of this slag truck with the one on the preceding 
page will serve to illustrate the difference between the ordinary screw 
dump and the screw dump with the Fitts ]iatent worm releasing 
device. With the former, to return the bowl to the upright position 
after dumping, the screw must be turned, while in the latter the 
movement of the lever shown just above the brake hand wheel dis¬ 
engages the screw from the worm wheel, and the pot automatically 
rights itself by gravity. The worm, instead of being journaled in 
the yoke, is journaled in blocks keyed to a shaft which takes the 
place of the screw or worm in the simpler construction, and the 
hand lever being also keyed to this shaft serves to move it into and 
out of engagement with the worm wheel. 

In the construction shown above, the separate gear is dispensed 
with and the rack, now made with diagonal teeth, engages the lower 


side of the worm wheel. 














COLORADO 

IRON WORKS CO 


SLAG TRLCKS. 


135 


Screw Dump Slag Truck. 

I Ills sla^’ truck lias an elliptical bowl of 4:5 cubic feet capacity 
and is e(pii])])e(l with the most imiiroved conveniences. The arrange- 
nuait of the ])latforni and brakes^ such as we place on one or both 
ends of our slag trucks, is well shown in the illustration, and the 
constrnction of the Fitts ])atent worm release mechanism is also 
clearly broimlit out. 



FIG. 117. 45 CU. FT. ELLIPTICAL BOWL SCREW DUMP SLAG TRUCK. 

The bowl is duni]>ed by o])eration of the crank attached to the 
end of the worm, but in righting the pot it is not necessary to reverse 
this o])eration, as is the case with the ordinary screw dump mechan¬ 
ism, but the de])ression of the latch lever disengages the worm from 
tlie worm wheel and the pot returns to the u])right position auto¬ 
matically, the center of gravity being below the center of support 
when the pot is empty. 

The manner in which the bowl is carried in the trunnion ring 
can be clearly seen in the illustration. The weight of the bowl is 
carried bv brackets on the enels and seats on the sides, and the bowl 
is held in jilace by dogs fitted to square holes, the dogs being held 
in turn by keys. The height of this truck from top of rail to top of 
howl is fifty inches. 








1150 


SLAG TTUICKS. 


COLORADO 

IRON WORKS CO 


Screw Dump Slag Truck. 

The sltic truck liorc sliowu is (iiiitG siiiiihir to the 44 cubic foot 
truck already described but is eijuijiped with a screw' duiu])iug instead 
of a lever dumping’ niechanisni. The general dimensions are similar, 
but intending ]uirchasei’s should, of course, obtain exact dimensions 
from us if there is limited room. Mention of this is made because 
the particular slag truck illustrated here is not built so low' as it could 
be should necessity reipiire it, nor so low as the truck show'ii on page 
131 and referred to above. 



FIG. 118. 44 CU. F'P. SEMI-EFLIPTICAL, BOW'L SCREW DUMP SLAG TRUCK. 


The semi-elli])tical form of the bowd show’n in the illustration 
on this page enables large ca]iacities to be obtained, at the same time 
keeping the overall height as small as possible, and w'e have built 
trucks of this form having sixty cubic feet capacity. 

The car show’ii is w'ithout platform or brakes, but any require¬ 
ments in this res])ect, as w'ell as in other details, can easily be met. 
The flanged w'heels wdiich roll on the transverse rails take the entire 
w'eight of the bow'l and a gear w'ith rack having diagonal teeth serves 
to bring the bow'l back over the center of the truck w'hen in the 
upright })osition. The angle of the teeth of the gears is the same 
as the angle of the thread of the w'orni. so that the gear w'hich engages 
the w'orm can be cut to tit the latter. Although show'ii w'ithout it, 
the Fitts patent w'orm release can be sup]died, if desired. 








COLORADO 

IRON WORKS CO 


SLAG CAirrS. 


1:37 



Hand Slag Carts. 


FIG. 119. STANDARD HAND SLAG CART. 

The above illustration shows the general stvle of the standard 
hand slag cart used at many smelters. We make them with many 
sizes and styles of hoAvls, with or without roller bearings, the wheels 
and forged parts yarying in size to suit the pot. A number of our 
bowls are shown in section on the following page. They are made 
of the same mixture as our cast iron jackets, which we haye found 
yery sipierior to resist sudden and repeated temperature changes. 

Below is shown a special slag cart haying a separable bowl 
with feet to hold it in the upright ]iosition. We haye made them 
at times where it was desired to allow the slag to settle and solidify 
in the pot, lint they can only be used on a relatiyely level floor, and 
the dead weight added by this construction is considerable. It 
should be noted that this ]iot cannot be dumped in the ordinary way. 



FIG. 120 . SPECIAL HAND SLAG CART WITH SEPARABLE BOWL. 



SLA(} CAirr IJOWLS. 


COLOR ADO 

IRON WORKS CO 


Hand Slag Cart Bowls. 



2 CU. FT. CAPACITY 3^ CU. FT. CAPACITY 

FIG 121. DIMENSIONS AND CAPACITIES OF SDAG BOWLS. 




















































































































































COLORADO 

IRON WORKS CO 


:SrATTK POTS. 


1:50 


Matte Settling Pots. 

1 he illustration on this page is of a mounted matte settling pot. 
e make them of our sjiecial water jacket mixture of cast iron, 
of t) 1 - 0 , 7^/h and 8|/h cubic feet cajiacitv. They are furnished with 
or without roller hearings and are ironed n]^ like an ordinary hand 
slag cart. 

I hey are used at lead smelters where the matte fall is light, 
being placed under the slag s])ont of the blast furnace, the matte 
settling to the liottom and the slag overflowing into the ordinary 
hand slag carts. They are arranged so that the spout can be placed 
on either side, a ])atch being furnished for the notch not in nse. 



FIG. 122. MOITNTED MATTE SETTLING POT. 

Idle principle underlying their nse is the same as that of the 
forehearth or settler, but their form is more convenient and portable. 
In operation, one of these matte pots is kept in service until prac¬ 
tically full, when it is removed and the matte allowed to cool in it, 
its place being taken by another similar ])ot. When the matte has 
solidified it is removed from the pot and conveyed to the furnace 
feed door for resinelting, or crushed for roasting prior to resmelting. 

A forehearth is of course a necessary adjunct to every large lead 
blast furnace, and to every furnace where the matte fall is heavy, 
but under the conditions stated, these matte pots are very serviceable 
and they are indeed sometimes used in connection with a forehearth, 
between it and the hand slag carts to act as additional means for 
preventing loss of matte. 






140 


MATTE I’OTS. 


COLORADO 

IRON WORKS CO 


The duty on matte settling ])Ots being usually very severe, we 
have supplied niany having vertical ribs radiating from the center 
at the bottom to a horizontal rib encircling the upper edge, as shown 
below. These have proved very satisfactory, the life of the bowl being 
matei’ially increased over that of the ordinary unidbbed bowl. 



FIG. 123. MOUNTED MATTE SETTLING POT WITH RIBBED BO^VL. 

The illustration below shows a mould for either matte or black 
copper. The bowls are made of the best grade of cast iron, very 
heavy, and are mounted on wdieels after the manner of a hand slag 
cart. We also have patterns for shallow matte moulds with flat 
bottoms, to facilitate breaking up the matte for sacking or crushing. 

We have a large and varied assortment of patterns for lead 
bullion, copjier and copper matte moulds. They are usually lettered 
with the name of the company in the bottom. 



FIG. 124. MOUNTED COPPER OR COPPER MATTE MOULD 






COLOR ADO 

IRON WORKS CO 


ISfATTp: ]\rOUT.I)S. 


141 


\\ e show ill the engraviiig below our mounted ribbed matte 
mould. e have bad the advantage of much ex]ierience in the use 
of properly designed moulds for cojiper matte, and while we have 
many patterns of ditferent forms, we have found the one illustrated 
to be very satisfactory and in favor with furnacemen. A ]dain band 
slag cart is used but the bowl is thoroughly ribbed on the outside 
as the cut shows. 



FIG. 125. MOUNTED MATTE MOUED.. 

We also show on this page a stationary matte pan, the end of 
which is placed under the matte tap of the forehearth. It is made 
of the best grade of cast iron, very heavy, and in sections, so that 
any desired length can be made up. The form is shallow, and the 
matte consequently cools ra])idly and is easy to break up. Trans¬ 
verse ribs at the joints between the sections prevent the matte from 
running into a following section until the preceding one is partially 
filled. 



FIG. 126. SECTIONAL STATIONARY MATTE PAN. 








142 


OIv’K CAIJS. 


COLORADO 

IRON WORKS CO 


Ore Cars. 



Cars are largely used in and about sineltiiig ])lants, and while 
we niannfaetnre some thirty or forty styles and have exeelkmt fanil¬ 
ities for this elass of work, we show only a few favored designs. 

The roll side dump car 
shown in the annexed illus¬ 
tration is very convenient in 
many situations and we build 
it in lar£>’e nnnd)ers. The 
center of gravity is above the 
]joint of support when full 
and below it Avhen empty, so 
that it is easily dnmped, and 
vdien empty, self righting. 
As shown, it has hand brakes 
and is arranged to be handled 
in a train, but its construc¬ 
tion in these resi'»ects can l)e 

FIG. 127. ROLL SIDE DUMP CAR. . . ‘ . 

varied to suit the special pur¬ 
pose it is intended to serve. It is a very convenient form for charg¬ 
ing blast furnaces and is made of from 20 to 100 cubic feet capac¬ 
ity ; gauge of track 24 to 48 inches. 


We sho\v herewith an¬ 
other car for carrying ore, 
flnx and fuel, which also 
dumps to the side. The 
side of this car is hinged at 
the top and fastened wdth a 
latch at the bottom, so that 
by raising the latch the con- 
tents of the car slides out 
l)y reason of the bottom 
being inclined. We make 
these cars of any desired 
size, and to dump on one or 
both sides. The one illus¬ 
trated is a single side dump. 



FIG. 128. SIDE DUMP CAR. 













COLORADO 

IRON WORKS CO 


OK’E CAKS. 


1 



FIG. 129. BOTTOM DUMP CAR. 

able iron fittines beiiii>‘ used. Tlicv art 

O o «/ 

roller bearing wheels and foot braki 
nsnallv built as shown, with one w 

t' / 

other loose. 


The annexed illustra¬ 
tion shows a ear which dunijis 
troni the hottoni and throne;!! 
the track. Ft is designed for 
cases where it is desired to 
discharge into a bin iniinedi- 
jitely below the track and is 
])articnlarly convenient for 
feeding reverberatory and 
revolving roasting furnaces, 
transporting crushed ore 
from the sul])hide mill to the 
roaster beds, etc. These cars, 
like all we build, are thor- 
ouffhlv well made, no malle- 
made of any required size, with 
5 if desired, although thev are 
heel pressed onto the axle, the 



FIG. 130. AUTOMATIC DUMPING CAR. 


The above car is designed es])ecially for carrying matte, slag 
settlings and the various materials requiring resmelting which accu¬ 
mulate on the tapping floor, to the blast furnace feed floor. It is to 
operate on an inclined tramway, and dumps automatically by a trip 
at the desired point. It is made of steel throughont except the wheels 
and boxes, and in several sizes to meet different recpiirements. 







144 


HOISTS. 


COLORADO 

IRON WORKS CO 



FIG. 131. DOUBLE FRICTION BELT DRIVEN HOIST. 



The above illustration shows a simple and very efficient belt 
driven double pajier friction hoist. It is used at many larc^e lead 
smelters for operating the automatic dumping car shown in Tig. 130 
on the inclined tramway between the tapping and feed floors. In 
addition to a large number sold, we have had one in very satisfactory 
use at our works for many years. There is nothing better for pur¬ 
poses of the kind mentioned. 


FIG. 132. SINGLE FRICTION BELT DRIVEN HOIST. 

\\ e also build a belt driven hoist with single paper friction as 
shown in the lower illustration on this page. Although cheaper and 
of less capacity than the double friction hoist, it is very satisfactory 
in operation. 






COLORADO 

IRON WORKS CO 


110ISTS T r F? XT A B T.ES. 


145 



FIG. 133. SPECIAL ELECTRICALLY DRIVEN HOIST. 


Tlie above enoTaving shows a special electrically driven hoist for 
operating’ the matte settling system described on ])ages 12d and 124. 
The entire operation of the tramway is performed by this hoist, the 
raising, lowering and racking of the trolley being manipulated by the 
clutch lever on the end of the drum shaft, the brake lever and the 
electric controller. The worm is of bronze, and b<ith it and the worm 
wheel have machine cnt teeth. 



FIG. 134. BALL BEARING TURNTABLE. 


The above outline drawing shows a heavy, cast-iron, ball-bear¬ 
ing turntable for use in turning slag trucks or other heavy loads. The 
top plate is well ribbed, and the ball races in both top and bottom 
plates are turned out, using tinished and hardened steel balls, thus 
making an easily operated turntable. If preferred, these tables can 
be cast with rails on the up]ier face in order to avoid the wheels 
riding upon their flanges when ]iassing over them. We can furnish 
them for any gauge of track or wheel-base centers desired. 



















































140 


CIlAJfGTNC; B[IGGTP:S. 


COLORADO 

IRON WORKS CO 


Charging Buggies. 



FIG. 135. COKE BARROW. 

We show herewith a coke barrow such as usually employed. It 
has two wheels aud is of large capacity, owing to the great bulk of 
coke as compared with most other material. 

The charging buggy also illustrated on this page is built of ten 
aud twelve cubic feet capacity. The bottom of the body is provided 



FIG. 136. FURNACE CHARGING BUGGY. 

with a steel lining to take the wear from the bottom proper. The 
wheels are made Avith steel spokes of oval section, steel tires and cast 
iron hubs Avith plain or roller bearings. 














COLOR ADO 

IRON WORKS CO 


CIIAlJGTXr, SCALES. 


147 


Furnace Charging Scales. 


^\ e ha\e supplied Strait scales fur several years, and have been 
pleased with tlie satisfaction they have given. These makers have 
Gil gieat cittciitioii to clGtailSj among which may bo meiitioiiGcl the 
provision for kee]nno- dirt from enteriiio- tlie scale and a special form 



FIG. 137. MULinPLE BEAM CHARGING SCALE. 


of self-locking poise which prevents accidental change in setting by 
the j arring caused by travel over the platform. The frame and plat¬ 
form are of iron, style 11, being like style A, but heavier, for weighing 
larger loads. 

DESCRIPinON OP STRAIT CHARGING SCALES. 


STYLE 

Number 

Number of 

Capacity of 

j Subdivision of 

Size of 

Beams 

1 

Each Beam 

1 Beams 

Platform 

A 

450 

1 to 8 

1,500 lbs. 

5 pounds 

48-in, X 48-in. 

B 

452 

1 to 8 j 

2,000 lbs. 

10 pounds 

48-in. X 48-in. 












































(; V N K I j A1 - K Q T' 11 ‘ :\ 11^: n 'r. 


COLORADO 

IRON WORKS CO 


US 


Miscellaneous Equipment. 

It is iiiiiiGcessarj, and in¬ 
deed iinpossiljle, to illustrate or 
describe the various standard 
cquij^uiient which is used or may 
l)e ])rofitahly used in and about 
a smelting ])lant. 

Platform elevators are used 
in some smelting plants, both 
lead and copper, for returning 
matte, foul slag, etc., to the feed 
floor. We furnish them of any 
desired capacity, with single or 
double platform, and to be oper¬ 
ated by electricity, by belt from 
a line shaft, or by the hydraulic 
plunger system. 

We build brakes for the operation of gravity surface tramways, 
which, where the grade is suitable and a straight track can be laid, 
offer probably the cheapest means of transporting ore. power 

is required and one man at the brake can handle a large tonnage. 
We shall be glad to answer any inquiries on this subject. 

Crushing, conveying, elevating and other equipment has been 
excluded from this catalogue, which is intended to be restricted to 
smelting; but it should be remembered that Ave fullv cover the ore 
treatment field and manufacture a very extensive line. 

There is much in the nature of Avorking tools and appliances 
Avhich, AAdiile strictly for smelter use, is not thought of sufficient 
importance to Avarrant its inclusion here, on account of a desire to 
keep the size of the book Avithin reasonable limits. All such, includ¬ 
ing assay and laboratory equipment, Ave either manufacture ourselves 
or are in position to supply of a class suitable for the Avork to be 
performed. LikcAvise, machinists’ tools, blacksmiths’ tools and gen¬ 
eral supplies Avill be furnished, and A\^e shall be glad to furnish appro¬ 
priate lists of such at any time for plants of various sizes. 



FIG. 138. PLATFORM ELEVATOR. 






















COLORADO 

IRON WORKS CO 


A U T O AIA 'FTC S A AIP LE I{ S. 


149 


Automatic Samplers. 

The samplers now used in the majority of the large smelters and 
custom samplers in the TTiited States, (linada and ]\rexico are of the 
Vezin type, and we call special attention to the compact and self-con¬ 
tained features of onr desio’n. 
Onr Vezin sampler is built en¬ 
tirely of iron and steel, to 
deliver either single or dupli¬ 
cate sam])les, cutting out 
either 5 per cent, or 10 per 
cent, of the ore passed through. 
They are made in two sizes, 
MG-inch and 48-inch, the for¬ 
mer being suitable for ore 
crushed to l^V-inch cubes and 
tiner, and the latter for ore up 
to ^l/o-inch cubes, the size de¬ 
pending on the size of the ore 
to he sampled, the capacity of 
either size being ample for any ordinary duty. The illustration is 
that of the duplicate sampler. The single sample machine differs 
from it only in the ahsence of the two chutes which cut out the extra 

sample. 

The Jones sampler, also here shown, is a very convenient device 
for laboratory use in dividing small samples of pulp. Tt is probably 



the most generally used of all the 
small samplers which have been 
offered for a like purpose, and 
is so simple in operation as to 
require no detailed description. 
The one shown is very substan¬ 
tially made of cast iron and steel 
and will withstand the rough 
usage it is liable to be subjected 
to. It wmighs, with pans, 250 
pounds. 



FIG. 140. JONES SAAIPLER. 








150 


COLORADO 

IRON WORKS CO ' 


KKVKIvMJKI^ATOIfY S.M KI/l'ING 


FURXACER. 


Reverberatory Smelting Furnaces. 

Keverlxu’atory smelting fnriiaei's are largely used in copper 
matting Avliere the amount of tines, concentrates, etc., is so great 
as to make the charge nnsnitalde for treatment in the blast furnace. 
A reverberatory is also a valuable adjunct to a blast furnace smelting 
])lant, as in addition to relieving the blast furnace of the fines and 
thus increasing its s])eed, it Avill also take care of the flue dust; but 
with a reverberatory in use there Avill naturally be less flue dust from 
the blast furnace. 











FIG. 141. REVERBERATORY COPPER MATTING FURNACE. 


It does clean work, but its cost of operation is not to be com- 
]iared Avith that of the blast furnace, excejit in those rare instances 
Avhere the scale of operations has been very large and has been accoin- 
iianied l>v other faAmrable factors. The very large reA^erberatories 

It f 

used in accomplishing these unusual results are not of general appli¬ 
cability, and for this reason Ave liaA^e chosen for illnstration a furnace 
of moderate size, such as is suitable for use in a Avider field. AYe are 
nevertheless prepared to build reATrberatories of any size. 

The furnace shoAvn is one of the best construction, the entire 
hearth being built in a steel pan, the sides of Avhich extend up about 
th ree feet, carried by a series of I-beams resting on Ioav brick piers. 
The hearth Avails to their tops, also the entire fire-box are incased in 
cast iron plates, thereby enclosing the entire furnace in iron and steel 
and preventing molten matte or slag from see]ung through the Avails 
and doAAui into the foundation. 


1 


























































































































COLORADO 

IRON WORKS CO 


R KVEinS F.KATORY S:^I ELTINCt EERXACES. 


151 


Ill very lon^- reverberatory smelting furnaces, a deep tire-box is 
used, resulting in incomplete combustion and the ])ossibility of se¬ 
eming the desired long tlanie by the admission of combustion air in 
the vicinity of the bridge Avail. 

here tnel is exjiensive or of an inferior (piality, it can be 
burned to much better advantage, both as to etfectivcness and cost bv 
hrst coiiATrting it into ])rodncer gas. 



FIG. 142. REVERBERATORY COPPER MATTING FURNACE. 


.V separate gas ])roducer installation introduces considerable 
complicatioig but Avhere it is built as part of the furnace proper, these 
complications are aAmided and the sensible heat in the gas is con¬ 
served and utilized. 

Like onr reverberatory smelting furnaces of the ordinary type, 
these are designed and constructed in the best possible manner, the 
interior contour being suited for the particular conditions under 
which they are to operate. 

We su])])ly the complete iron work for reverberatory furnaces, 
Avith draAvings for their ]iro]ier erection at the site of operations, and 
solicit corres]iondence concerning them. 




































































































































































Reverberatory Roasting Furnaces. 


52 


E E K15 E J; A T O K Y U O A S1' IN CJ 


FURNACES. 


COLOR ADO 

IRON WORKS CO 



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COLOR ADO 

IRON WORKS CO 


HKVOT.VING COASTING CYTJNDEKS. 


158 


Bruckner Roasting Cylinders. 

dlie Ih-liekner roasting cylinder is ])robably the most popular 
of all revolving roasters nsed in lead smelting. ' Onr standard sizes 
aie () X 12, 7 x 1(5, 8 i/b ^ <itid 8 V 2 ^ feet, taking charges of 
8 to 4, G to 7, 18 to 17, and 20 to 25 tons res])ectively. The capacity 
per day dei)ends on the percentage of snlphnr in the charge and the 
l)ercentage of snlphnr i)ermissible in the roasted product. The time 
of treatment of a charge varies from three to forty-eight hours. 



FIG. 144. 81 / 2 x 261/2 FT. BRUCKNER ROASTING CYLINDER. 


The engraving is from a ])hotogTaph, and shows the worm and 
spur gearing nsed to reduce the speed to one revolution in about forty 
minutes, to jirevent excessive dust losses while turning the ore over 
to expose it to oxidation. 

The tire-boxes, not shown, are either movable or stationary, 
movable when the sul|)hnr content is high enough for roasting to 
proceed Avithont extraneous heat after the charge has been ignited. 
The tAA'elve-foot size has but tAvo openings, opposite each other, one 
for feeding and one for discharging. The larger sizes have four 
ojienings. Charging ho]ipers, not shoAvn, are furnished to be siis- 
]iended over the openings, these being of a suitable size to hold one 
charge. Coal hopjiers can also he furnished to be placed over the 
fire-boxes. Although Ave also build the AVhite-HoAvell and Oxland 
reAnlving roasters, they are comparatively little used in connection 
Avith smelting. 







154 


c o p I’ p: I? c () N i: R t e k s . 


COLORADO 

IRON WORKS CO 


FIG. 145. 


Sxll FT. HYDRAULICALLY 


OPERATED CONVERTER. 









' COLORADO 

IRON WORKS CO 


CD I‘ I’ E i; CO X VE H'i’ ERS. 


1 5 T) 


Copper Converters. 

I e are prepared to nndertake the design and equipment of com- 

I plete copper eonverting plants for bessemerizing copper matte. AVe 
I manufacture all suclq with the exception of blowing engines. 

Copper converters are of two general tvpes, the Parrot, which is 
1 barrel-shaped, placed vertically and swings on trunnions like the ordi- 
I nary iron converter, and another, known as the horizontal or trough 
converter. The size and method of operating copper converters have 
j progressed steadily since the first introduction of this method and 
converters are now the almost universal means for desulphurizing 
copper matte where any considerable amount is treated. 

A converter plant can not be profitably operated, except on a 
fairly large capacity, and it is customary for smelters of moderate 
size to sell their matte to large plants having the equipment. 

The principal methods of mechanical operation of converters 
are by electricity and by hydraulic power. We have chosen for illus¬ 
tration one of the latter, of the trough type, and desire to draw spe¬ 
cial attention to the compactness and rigidity of the stand construc¬ 
tion. The entire operating mechanism is self-contained, the hydrau¬ 
lic cylinder and the cylinder controlling valve being carried by one 
of the sole plates. The controlling valve is operated by a large hand 
wheel with a toothed quadrant to which is connected the valve stem, 
thereby placing the range of movement of the converter shell under 
absolute control of the operator. The thrust of the gear on the end 
of the cvlinder is divided uniformlv between two guide rollers at 
the top of the guide roller stand. At the lower end of the two 
diagonal brace bars is provided an eccentric with which the vertical 
rack can readily be throAvn in and out of gear. The roller-wheel 
boxes are adjustable by means of steel Avedges. Where tlie details 
of converter construction are left to us, Ave build them of the best 
materials and in a most thorough manner throughout, as thev are 
subjected to very severe duty and should be built accordingly. 

Space does not permit the description of the various accessory 
apparatus and machinery AAdiich goes into the Avell appointed con- 
A’erter plant, but inquiries concerning it Avill be cheerfully ansAvered. 



inr* 


COLOR ADO 

IRON WORKS CO 


CIM’ KT.] I X(i FU K N ACES. 


FIG. 146. DOUBLE ENGLISH CUPELLING FURNACE WITH TILTING TESTS. 








































































COLORADO 

IRON WORKS CO 


CUPELLING FURNACES. 


157 


Cupelling Furnaces. 

In I ig. 116 we show a double English enpelling furnace Avith 
tilting test ])ottoins. e build them single as well as double, the con¬ 
struction of the single furnace being the same, except that one side 
is omitted. The test bottoms are supported bv steel frames, the 
front of AAdiich can be tilted by a hand-Avheel and screw convenientK’ 
located. In this form, a. separate car is used for handling the tests. 

Cu])elling furnaces are largely used in refining lead-silver bul¬ 
lion, and we haA^e also supplied them in connection Avith lead smelters 



FIG. 147. CUPEL TEST CARRIAGE AAUTH 36" x 4S" TEST RING. 

Avliere there Avas a deficiency of lead for the blast furnace charge. 
They are then operated for the production of litharge, but the con¬ 
centration of the bullion into a. more valuable shipping product is 
also of advantage. 

In Fig. IIT Ave shoAv another form of test carriage Avith an ordi- 

O c' 

nary test ring. In this form the carriage remains in position and 
the four inde|)endent screAvs at the corners insure a close fit betAveen 
the test and the compass ring. The plain test ring is used Avhere 
the corrosive action of the litharge does not destroy the filling Avith 
sufficient ra|)idity to justify the inconvenience of maintaining a cir¬ 
culation of Avater in a jacketed test ring, although there are inaiiA’ 
cases in Avhicli jacketed test rings are found preferable on account of 
the prolonged life of the filling. 



COLORADO 

IRON WORKS CO 


Index. 

PAGE 

Aiiiiouncemeiit . 3 

Arch bar mantels . 48 

Barrows^ coke . 146 

Black copper smelting . lo 

Blast furnaces, copper . 74 

Blast furnaces, silver-lead . 53 

Blast furnaces, structure of . 42. 

Blast gates . 110 

Blowers . 109 

Bosh of the blast furnace. 44 

Bottom dumping ear . 143 

Bowls, slag cart . 138 

Bruckner roasting cylinders . 153 

Buggies, charging . 146 

Ca 2 :)acities, minimum, blast furnace . 41 

Cars . 142 

Carts, matte . 139 

Carts, slag . 137 

Chambers, dust . 105 

Charging buggies . 146 

Charging scales . 147 

Coke barrows . 146 

Converters, copper . 155 

Converting, copper . 14 

Coolers, lead . 116 

Copper, black, smelting . 15 

Copper matte smelting in blast furnaces . 8 

Copper matte smelting in reverberatories . 11 

Copper matting furnaces . 74 

Copper moulds . 140 

Copper refining . 14 

Cupellation . 20 

Cupelling furnaces . 157 

Bata required for estimates. 40 

Drawing of sampling plant . 22 

Drawings of smelting plants . 23 

Dump ears . 142 

Dust chambers . 105 

Electrolytic copper refining . 14 

Elevators, platform . 148 

Estimates, information required for . 40 

Flues, dust . 105 

Forehearths . 117 

Furnace hoods .. 106 

















































COLORADO 

IRON WORKS CO 


INDEX. 


159 


PAGE 

Funiaces, blast, for copper ores . 74 

Furnaces, blast, for lead ores . 53 

Furnaces, cupelling . 157 

Furnaces, reverberatory roasting . 152 

Furnaces, reverberatory smelting. 150 

Furnaces, roasting . 152 

Gas escape valve, automatic . 47 

Gates, blast . 110 

Gold recovery in smelting .9, 18 

Granulation of slag. 121 

Gravity surface tramways . 148 

Gross patent trap S])out . 52 

Hoists . 144 

Hoods, furnace . 100 

Hot blast smelting . 28 

Hot blast stoves . 113 

Information required for estimating. 40 

Interior contour of blast furnaces . 44 

Jacket water, vaporization of . 35 

Jackets, end, with curved corners . 47 

Jones sampler . 149 

Kettles for lead furnaces . .. 116 

Lead coolers . 110 

Lead-silver blast furnaces . 53 

Lead smelting in blast furnaces . 15 

Lead smelting in reverberatories . 19 

JMantel frames . 48 

Matte boxes . 117 

JMatte carts . 139 

jMatte, copper . 9 

Matte moulds . 141 

IMatte pans . 141 

Matte settling and separating system . 123 

JMatte smelting in blast furnaces . 8 

JMatte smelting in reverberatories . 11 

JMatting furnaces, blast. 74 

Matting furnaces, reverberatory . 150 

JMoulds, copper . 140 

JMoulds, matte . 141 

Ore cars . 142 

Pans, matte . 141 

IMan of a. sampling works . 22 

Plans of smelting plants . 23 

Platform elevators . 148 

Pyritic smelting . 11 

lie lining, copj)er . 14 

Refining, lead . 20 

Repair work . 4 

Reverberatory roasting furnaces . 152 




















































IXDEX. 


COLORADO 

IRON WORKS CO 


IGO 

PAGE 

Reverberatory smelting, copper . 11 

Reverberatory smelting, lead . 19 

Reverberatory smelting furnaces . 150 

Roasting furnaces . 152 

Safety valves, gas escape . 47 

Samplers, automatic . 149 

Sampling . 20 

Sampling works, plan of . 22 

Scales, furnace charging . 147 

Scotch hearths, lead smelting in. 20 

Settlers . 117 

Settling pots, matte . 139 

Silver recoverv in smelting .9, 18 

Silver-lead blast furnaces . 53 

Silver-lead smelting . 15 

Slag cart bowls . 138 

Slag carts . 137 

Slag formation . 6 

Slag, granulation of . 121 

Slag trucks . 125 

Smelting, black copper . 15 

Smelting, copper matte . 8 

Smelting, hot blast . 28 

Smelting, lead-silver . 15 

Smelting plants, plans of . 23 

Smelting process, the . G 

Smelting, pyritic . 11 

Smelting, reverberatory copper . 11 

Smelting, reverberatory lead . 19 

Smelting, silver-lead . 15 

Speiss . 19 

Spouts, Gross patent trap . 52 

Stoves, hot blast . 113 

Superstructure of the blast furnace . lOG 

Surface tramways . 148 

Terms . 4 

Tools and supplies . 148 

Tramways, gravit}^ surface . 148 

Trap spout, Gross patent. 52 

Trucks, slag . 125 

Turntables . 145 

4'uyeres, blast furnace . 50 

U-pipe hot blast stoves . 113 

Valves, gas esca])e . 47 

Vaporization of jacket water . 35 

\'ezin sampler . 149 

Water jacketed girders . 49 

Water jackets with curved corners . 47 


THE W. F. ROBINSON PRINTING CO. 




















































































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DERY INC. 



170-948 

■o-Pleasc^^ N. MANCHESTER, 
INDIANA 4fi962 


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